Laser Cutters: Where’s The Point?

August 14, 2024 by Al Williams 31 Comments

It is funny how when you first start doing something, you have so many misconceptions that you have to discard. When you look back on it, it always seems like you should have known better. That was the case when I first got a low-end laser cutter. When you want to cut or engrave something, it has to be in just the right spot. It is like hanging a picture. You can get really close, but if it is off just a little bit, people will notice.

The big commercial units I’ve been around all had cameras that were in a fixed position and were calibrated. So the software didn’t show you a representation of the bed. It showed you the bed. The real bed plus whatever was on it. Getting things lined up was simply a matter of dragging everything around until it looked right on the screen.

Today, some cheap laser cutters have cameras, and you can probably add one to those that don’t. But you still don’t need it. My Ourtur Laser Master 3 has nothing fancy, and while I didn’t always tackle it the best way, my current method works well enough. In addition, I recently got a chance to try an XTool S1. It isn’t that cheap, but it doesn’t have a camera. Interestingly, though, there are two different ways of laying things out that also work. However, you can still do it the old-fashioned way, too. Continue reading “Laser Cutters: Where’s The Point?” →

LightBurn Turns Back The Clock, Bails On Linux Users

July 31, 2024 by Tom Nardi 217 Comments

Angry Birds, flash mobs, Russell Brand, fidget spinners. All of these were virtually unavoidable in the previous decade, and yet, like so many popular trends, have now largely faded into obscurity. But in a recent announcement, the developers of LightBurn have brought back a relic of the past that we thought was all but buried along with Harambe — popular software not supporting Linux.

But this isn’t a case of the developers not wanting to bring their software to Linux. LightBurn, the defacto tool for controlling hobbyist laser cutters and engravers, was already multi-platform. Looking forward, however, the developers claim that too much of their time is spent supporting and packaging the software for Linux relative to the size of the user base. In an announcement email sent out to users, they reached even deeper into the mid-2000s bag of excuses, and cited the number of Linux distributions as a further challenge:

The segmentation of Linux distributions complicates these burdens further — we’ve had to provide three separate packages for the versions of Linux we officially support, and still encounter frequent compatibility issues on those distributions (or closely related distributions), to say nothing of the many distributions we have been asked to support.

We’re not sure how much of their time could possibly be taken up by responding to requests for supporting additional distributions (especially when the answer is no), but apparently, it was enough that they finally had to put their foot down — the upcoming 1.7.00 release of LightBurn will be the last to run on Linux.

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Faux Silkscreen On A PCB Made With A Laser Cutter

March 18, 2024 by Lewin Day 13 Comments

If you’re getting PCBs professionally made, silkscreen usually comes free as part of the package. However, if you’re making your own, the job is on you. [Tony Goacher] makes his own PCBs on a CNC router, so he’s not getting any silkscreening as part of that bargain. But he wondered—could he do something analogous with a laser cutter?

The answer is yes. The silkscreen layer was first exported from DesignSpark, with the file then sent to LightBurn to prep it for laser cutting. The board outline layer was first engraved on to a piece of scrap as an alignment aid. Then, the board was placed in the laser cutter, with the silkscreen scorched directly on to the fiberglass.

The results are encouraging, if imperfect. [Tony] says he ran at “quite fast speed at quite high power.” The markings are all there, but they’re a little melty and difficult to read. He noted at lower speeds and lower power, the results were a bit more readable.

PCBs aren’t really an ideal engraving or laser marking material, but this technique could be servicable for some basic markings on DIY PCBs. We look forward to seeing how [Tony] improves the process in future. Video after the break.
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All I Want For Mr. Christmas Is Some New Music

January 12, 2024 by Kristina Panos 7 Comments

It’s true — you really can find anything (except maybe LEGO) in thrift stores. When [thecowgoesmoo] picked up a Mr. Christmas Symphonium music box one day, they knew they wanted to make it play more than just the standard Christmas and classical fare that ships with the thing.

So they did what any self-respecting hacker would do, and they wrote a MATLAB script that generates new disk silhouette images that they then cut from cardboard with a laser cutter. They also used various other materials like a disposable cutting mat. Really, whatever is lying around that’s stiff enough and able to be cut should work. You know you want to hear Van Halen’s “Jump” coming from a tinkling music box, don’t you? Be sure to check out the video demonstration after the break.

If you don’t want to wait around until a Mr. Christmas lands in your lap, why not make your own hand-cranked music box and accompanying scores?

Continue reading “All I Want For Mr. Christmas Is Some New Music” →

Man playing custom zither made with a laser cutter.

Laser Cut Zither Instrument Kicks It Old World Style

December 14, 2023 by Drew Littrell 4 Comments

Learning to play an instrument takes a certain level of dedication — and you can add another layer of dedication on top of that when it’s an instrument not found at your local Guitar Center. But it’s an entirely new level of dedication when someone crafts the instrument from scratch. If you’re looking for an example, check out this custom wooden zither [Nicolas Bras] built from laser cut parts.

The basic design of the instrument utilizes the sloted interlocking edges that are then glued together in lieu of traditional fasteners. Standard sized guitar tuning pegs and the accompanying steel guitar strings were then strung across two laser-cut bridges held in place by the string tension alone. The project began as way for [Nicolas] to learn the capabilities of his newly acquired laser cutter, but he himself is no amateur when it comes to constructing one-of-a-kind musical instruments. Just last year, he created a zither with bungee cords from the hardware store.

Zithers are German in origin, though some of the earliest zither-like instruments date back to 400 BCE China. The laser cut version [Nicolas] created had five strings to hammer on, though the type used in classical music arrangements typically contain upwards of thirty strings. The zither family of instruments may have given way to the electric guitars of today — it’s always neat to see new tech leveraged to embrace some old world charm.

For more on the art of DIY music production, check out this post on myriad of DIY musical instrument builds all played in concert.

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This Laser-Cut One-Piece Wedge Tenon Locks Wood Joints Tight

December 4, 2023 by Dan Maloney 24 Comments

Woodworkers have always been very clever about making strong and attractive joints — think of the strength of a mortise and tenon, or the artistry of a well-made dovetail. These joints have been around for ages and can be executed with nothing more than chisels and a hand saw, plus a lot of practice, of course. But new tools bring new challenges and new opportunities in joinery, like this interesting “hammer joint” that can be made with a laser cutter.

This interesting joint comes to us from [Jiskar Schmitz], who designed it for quick, solid, joints without the need for glue or fasteners. It’s a variation on a wedged mortise and tenon joint, which strengthens the standard version of the joint by using a wedge to expand the tenon outward to make firm contact with the walls of the tenon.

The hammer joint takes advantage of the thin kerf of a laser cutter and its ability to make blind cuts to produce a tenon with a built-in wedge. The wedge is attached to a slot in the tenon by a couple of thin connectors and stands proud of the top of the tenon. The tenon is inserted into a through-hole mortise, and a firm hammer blow on the wedge breaks it free and drives it into the slot. This expands the tenon and locks it tightly into the mortise, creating a fairly bulletproof joint. The video below tells the tale.

While the hammer joint seems mainly aimed at birch plywood, [Jiskar] mentions testing it in other materials, such as bamboo, MDF, and even acrylic, although wood seems to be the best application. [Jiskar] also mentions a potential improvement: the addition of a ratchet and pawl shape between the wedge and the slot in the tenon, which might serve to lock the wedge down and prevent it from backing out.

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Take The Tedium Out Of Fabric Cutting, Make The Laser Do It

October 29, 2023 by Donald Papp 8 Comments

Fabric must be cut before it can be turned into something else, and [fiercekittenz] shows how a laser cutter can hit all the right bases to save a lot of time on the process. She demonstrates processing three layers of fabric at once on a CO2 laser cutter, cutting three bags’ worth of material in a scant 1 minute and 29 seconds.

The three layers are a PU (polyurethane) waterproof canvas, a woven liner, and a patterned cotton canvas. The laser does a fantastic job of slicing out perfectly formed pieces in no time, and its precision means minimal waste. The only gotcha is to ensure materials are safe to laser cut. For example, PU-based canvas is acceptable, but PVC-based materials are not. If you want to skip the materials discussion and watch the job, laying the fabric in the machine starts around [3:16] in the video.

[fiercekittenz] acknowledges that her large 100-watt CO2 laser cutter is great but points out that smaller or diode-based laser machines can perfectly cut fabric under the right circumstances. One may have to work in smaller batches, but it doesn’t take 100 watts to do the job. Her large machine, for example, is running at only a fraction of its full power to cut the three layers at once.

One interesting thing is that the heat of the laser somewhat seals the cut edge of the PU waterproof canvas. In the past, we’ve seen defocused lasers used to weld and seal non-woven plastics like those in face masks, a task usually performed by ultrasonic welding. The ability for a laser beam to act as both “scissors” and “glue” in these cases is pretty interesting. You can learn all about using a laser cutter instead of fabric scissors in the video embedded below.

Continue reading “Take The Tedium Out Of Fabric Cutting, Make The Laser Do It” →