A Laser Cutter Challenge

September 14, 2011 by Brian Benchoff 14 Comments

When the Louisville hackerspace LVL1 was discussing the purchase of a new laser cutter, a member said, “I could build one before you get around to buying one.” The gauntlet was thrown down, a challenge was set, and the race was on to build a tiny laser cutter before the hackerspace took delivery of their new laser cutter.

The mechanical aspect of the build is fairly simple. The X axis is simply a stepper motor, threaded rod and laser module mounted on a carriage. This carriage moves along the Y axis with the help of two stepper motors for either side. Everything was mounted on more perfboard than reason would suggest.

For the electronics of the project, three motor drivers were made with a few logic chips and the laser firing relay was stolen from test equipment developed for LVL1’s trans-Atlantic balloon build. Motor and laser control was handled by an Arduino to keep the build simple because the contest was over after the first laser was finished cutting a square.

LVL1 is now working on a second version of the winner of the laser cutter challenge. They’re planning on a touchscreen interface that will cut a plastic blank about the size of a credit card. We can’t wait to see the results of that build.

Parametric Script Makes Laser Cutter Designs A Snap

July 31, 2011 by Mike Szczys 11 Comments

[Tinkerer] bought a small cupboard from an antique store to fit nicely into his kitchen decor. After getting it home, he realized that some of the cubbyholes had originally housed drawers. The originals were long gone but this provided an opportunity for him to make the replacements seen above.

The first design approach that popped into [Tinkerer’s] mind was to draw the pieces in an editor like Inkscape. Some consultation with others at the local Hackerspace led him to this script-based parametric SVG design tool. We jumped right in to give it a whirl, clicking on Load –> Construction (category) –> Better Box. Once you’ve chosen the script, click on ‘Parameters’ on the left column and enter the sizing you want for your box. When all values are correct, click the renter tab, then export it as a Scalable Vector Graphic.

We’ve lamented time and again about our lack of a laser cutter, so we were unable to test this out. But we can’t see why it wouldn’t reproduce the same results that [Tinkerer] achieved.

Accounting For Material Loss When Laser Cutting

July 12, 2011 by Mike Szczys 22 Comments

When you cut something out, you lose a bit of material in the process. Think of a table saw and the sawdust it produces, that’s the waste material lost in an area the width of the blade. It’s really easy to measure that, just measure the blade. But [James] started wondering about a good way to measure material loss from a laser cutter.

Why does it matter? If you’ve designed pieces that should fit together with each other, loss of material can lead to joints that aren’t tight. [James] figured out that the loss could be measured by making several cuts within a rectangular frame. You can see his test pieces above, with ten strips cut out of each frame. After the laser is done doing it’s work just slide all the pieces together and measure the opening created at one end. It helps to have an enhanced caliper to make the measurement easy to read. Now divide that distance by the number of laser passes and account for that dimension next time you design parts for the cutter.

Crosshair Aiming System For Your Laser Cutter

June 12, 2011 by Mike Nathan 13 Comments

diy_laser_crosshairs

[Rich] was having quite a bit of fun with his newly-acquired laser cutter, but was not impressed by the stock aiming laser that came with it. The problem with the built-in laser is that it did not actually follow the cutting laser’s path – instead, it has to be calibrated for a fixed focal length. This becomes problematic when engraving and cutting since they require different focal lengths, so it becomes a guessing game as to where the cutting laser will actually end up in respect to the aiming laser.

An additional optic module that solves this problem can be had for about $300, but after sinking $2500 into the laser setup, [Rich] was not inclined to purchase one. Instead, he bought a pair of cheap laser levels online and scavenged the line lens from one module, which was mounted on the laser cutter’s existing aiming laser. The second module was epoxied to the top of the cutting head, to create a set of cross hairs on the work surface.

As you can see in the video below, the hack works quite well, and the lasers are accurate at a variety of different focal lengths.

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Buying A Laser Cutter From China

April 14, 2011 by Jesse Congdon 58 Comments

We here at Hackaday have been pining over these cheap laser cutters on the e-bay. They are, however, just outside of the price range to make them worth ponying up for. [Stephen Hobley] however seems to have taken one for the team in his three part series, and is allowing us to live vicariously through is experiences.

Not surprisingly the price point leads to the potential for headaches. The units ship directly from China, and see their fair share of rough handling from package carriers. Broken/misaligned laser tubes are not uncommon (replacement tubes are prevalent). Shockingly the laser tube managed to survive the seven thousand mile journey! That only leaves a couple crucial modifications and careful cleaning and aligning to get the unit up and running. You didn’t think it would be that easy, did you?

To top off all the modifications adjustments and cleaning steps [Stephen] found (in part three) that his controller board was on the fritz. With a new one on the way from China, [Stephen] is debating either reverse engineering the included controller board or coming up with his own CNC solution. We could suggest quite a few alternate solutions ourselves.

We will be glued to [Stephen]’s blog for updates.

Stick around for a video of what we all really want to see, a laser burning stuff.

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Building A Zoetrope Using Kinect, Processing, And A Laser Cutter

March 19, 2011 by Mike Szczys 8 Comments

A zoetrope is a device that contains a disk full with a series of images that make up and animation. A couple of different methods can be used to trick the eye into seeing a single animated image. In the past this was done by placing the images inside of a cylinder with slits at regular distances. When spun quickly, the slits appear to be stationary, with the images creating the animation. But the same effect can be accomplished using a strobe light.

The disk you see above uses the strobe method, but it’s design and construction is what caught our eye. The animated shapes were captured with a Kinect and isolated using Processing. [Greg Borenstein] takes a depth movie recorded while someone danced in front of a Kinect. He ran it through a Processing sketch and was able to isolate a set of slides that where then turned into the objects seen above using a laser cutter.

You can watch a video of this particular zoetrope after the break. But we’ve also embedded the Pixal 3D zoetrope clip which, although unrelated to this hack, is extremely interesting. Don’t have a laser cutter to try this out yourself? You could always build a zoetrope that uses a printed disk.

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Laser-cut Noise Maker Resembles Violin

March 10, 2011 by Mike Szczys 8 Comments

This looks very much like a violin but it sounds very much like someone abusing a family of cats. [Ranjit] came with the idea of building a violin using laser cut parts. It doesn’t follow the normal curved shape we’re used to seeing with string instruments. This is because the parts were all cut from flat stock, including the sides of the instrument. The boxy shape that resulted invokes visions of early video game objects and is why this is called the 8-bit violin.

After the break you can see a video of [Bre Pettis] playing the laser-cut instrument. It’s pretty bad, but not in that five-year-old picking up an instrument for the first time sort of way. Yes the best violinists spend a lifetime honing their craft, but they also play on instruments hand carved by master Luthiers who also spend a lifetime perfecting their skills. Don’t get us wrong though, we think it’s just as much fun as that 3D printed guitar.

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