Trying To Build A Communications Device With A 1-Pound Laser And A 7805

May 20, 2024 by Lewin Day 28 Comments

You can get a red laser diode pretty cheap these days—as cheap as £1 in fact. [Beamer] had purchased one himself, but quickly grew bored with just pointing it at the walls. He decided to figure out if he could use it for some kind of communication, and whipped up a circuit to test it out.

To do the job, he designed a modulator circuit that could drive the laser without damaging it. The build is based around the common 7805 regulator and the venerable 555 timer IC. The 555 is set to pulse at a given rate with the usual array of capacitors and resistors. Its output directly drives the input of a 7805 regulator. It’s set up as a constant current source in order to deliver the correct amount of current to run the laser. The receiver is based around a photodiode, which should prove fairly straightforward.

[Beamer]’s still working on the full setup, but plans to use the laser’s pulses to drive a varying analog meter or something similar. Not every communications method has to send digital data, and it’s good to remember that! Video after the break.

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Stack of Si3N4-LiNbO3 forming the integrated laser and integrated into test setup (d). (Credit: Snigirev et al., 2023)

Fast Adjustable Lasers Using Lithium Niobate Integrated Photonics

August 4, 2023 by Maya Posch 14 Comments

Making lasers smaller and more capable of rapidly alternating between frequencies, while remaining within a narrow band, is an essential part of bringing down the cost of technologies such as LiDAR and optical communication. Much of the challenge here lies understandably in finding the right materials that enable a laser which incorporates all of these properties.

A heterogeneous Si3N4–LiNbO3 chip as used in the study. (Credit: Snigirev et al., 2023)

Here a recent study by [Viacheslav Snigirev] and colleagues (press release) demonstrates how combining the properties of lithium niobate (LiNbO₃) with those of silicon nitride (Si₃N₄) into a hybrid (Si₃N₄)–LiNbO₃ wafer stack allows for an InP-based laser source to be modulated in the etched photonic circuitry to achieve the desired output properties.

Much of the modulation stability is achieved through laser self-injection locking via the microresonator structures on the hybrid chip. These provide optical back reflection that forces the laser diode to resonate at a specific frequency, providing the frequency lock. What enables the fast frequency tuning is that this is determined by the applied voltage on the microresonator structure via the formed electrodes.

With a LiDAR demonstration in the paper that uses one of these hybrid circuits it is demonstrated that the direct wafer bonding approach works well, and a number of optimization suggestions are provided. As with all of these studies, they build upon years of previous research as problems are found and solutions suggested and tested. It would seem that thin-film LiNbO₃ structures are now finding some very useful applications in photonics.

(Heading image: Stack of Si₃N₄-LiNbO₃ forming the integrated laser and integrated into test setup (d). (Credit: Snigirev et al., 2023) )

The laser module shown cutting shapes out of a piece of cardboard that's lying on the CNC's work surface

Giant CNC Partners With Powerful Laser Diode

April 30, 2022 by Arya Voronova 13 Comments

[Jeshua Lacock] from 3DTOPO owns a large-format CNC (4’x8′, or 1.2×2.4 m), that he strongly feels is lacking laser-cutting capabilities. The frame is there, and a 150 W CO2 laser tube has been sitting in a box for ages – what else could you need? Sadly, at such a scale, aligning the mirrors is a tough and finicky job – and misalignment can be literally blinding. After reading tales about cutters of such size going out of alignment when someone as much as walked nearby, he dropped the idea – and equipped the CNC head with a high-power laser diode module instead. Having done mirror adjustment on a few CO2 tube-equipped lasers, we can see where he’s coming from.

Typically, the laser modules you see bolted onto CNC heads are firmly under three watts, which is usually only enough for engraving. With a module that provides 5 watts of optical power, [Jeshua] can cut cardboard and thin plywood as well he tells us even 10 W optical power modules are available, just that he didn’t go for one. We reckon that 20 W effective power diodes are not that far into our future, which is getting very close to the potential of the blue box “40 W but actually 35 W but actually way less” K40 laser cutters we cherish. [Jeshua]’s cutter is not breaking speed limits, but it’s built on what’s already there, and the diode is comparatively inexpensive. Equipped with a small honeycomb surface and what seems to be air assist, it’s shown in the video cutting an ornamental piece out of cardboard!

We hackers have been equipping CNCs with laser diodes for a while, but on a way smaller scale and with less powerful diodes – this is definitely a step up! As a hacker, you should have at least some laser cutting options at your disposal, and this overview of CO2 cutters and their availability can get you started. We’ve also given you detailed breakdowns about different sides of laser cutting, be it the must-have of safety, or the nice-to-have of air assist.

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Building A 1.4W Laser Pointer In A Tiny Housing

February 19, 2019 by Lewin Day 37 Comments

Laser pointers were cool for about 30 seconds when they first came out, before becoming immediately passé and doing absolutely nothing to improve the boss’s quarterly reports presentation. However, just as with boom boxes and sports cars, more power can always make things better. [Styropyro] was unimpressed with the weak and unreliable laser pointers he’d sourced from eBay, so gutted one and began a fresh build.

After fiddling with some basic 1mW eBay green lasers, [styropyro] had some fun turning up the wick by fiddling with the internal trimpots. This led to the quick and untimely death of the cheap laser diodes, leaving a compact laser pointer shell ripe for the hacking.

To replace the underwhelming stock components, [styropyro] chose a Nichia NDG7475 high-powered laser diode, fitting it into a small heatsink for thermal management. Current draw was far too high to use the original switch, so the stock housing’s button is instead used to switch a MOSFET which delivers the full current to the laser driver. To reach the higher output power of 1.4W, the laser diode is being run over specification at 2.3 amps. All this current draw would quickly overwhelm standard AAA batteries, so a pair of lithium polymer 10440 batteries are substituted in to do the job.

The build shows that with clever parts selection and some easy hand soldering, you too can build an incredibly dangerous laser pointer at home, that fits neatly in your shirt pocket. Alternatively, you might prefer something on the larger scale. Video after the break.

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[Ben Krasnow] Builds A One-Component Interferometer

December 13, 2018 by Dan Maloney 32 Comments

When we think of physics experiments, we tend to envision cavernous rooms filled with things like optical benches, huge coils in vacuum chambers, and rack after rack of amplifiers and data acquisition hardware. But it doesn’t have to be that way – you can actually perform laser interferometry with a single component and measure sub-micron displacements and more.

The astute viewer of [Ben Krasnow]’s video below will note that in order to use the one component, a laser diode, as an interferometer, he needed a whole bunch of support gear, like power supplies, a signal generator, and a really, really nice mixed-signal oscilloscope. But the principle of the experiment is the important bit, which uses a laser diode with a built-in monitoring photodiode. Brought out to a third lead, older laser diodes often used these photodiodes to control the light emitted by the laser junction. But they also respond to light reflected back into the laser diode, and thanks to constructive and destructive interference, can actually generate a signal that corresponds to very slight displacements of a reflector. [Ben] used it to measure the vibrations of a small speaker, the rotation of a motor shaft, and with a slight change in setup, to measure the range to a fixed target with sub-micron precision. It’s fascinating stuff, and the fact you can extract so much information from a single component is pretty cool.

We really like [Ben]’s style of presentation, and the interesting little nooks and crannies of physics that he finds a way to explore. He recently looked at how helium can kill a MEMS sensor, an equally fascinating topic.

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Robotic Laser Keeps Cat Entertained While You Hack

February 23, 2018 by Steven Dufresne 14 Comments

Whether it’s our own cat or a neighbor’s, many of us have experienced the friendly feline keeping us company while we work, often contributing on the keyboard, sticking its head where our hands are for a closer look, or sitting on needed parts. So how to keep the crafty kitty busy elsewhere? This roboticized laser on a pan-tilt mechanism from the [circuit.io team] should do the trick.

The laser is a 650 nm laser diode mounted on a 3D printed pan-tilt system which they found on Thingiverse and modified for attaching the diode’s housing. It’s all pretty lightweight so two 9G Micro Servos do the grunt work just fine. The brain is an Arduino UNO running an open-source VarSpeedServo library for smooth movements. Also included are an HC-05 Bluetooth receiver and an Android app for controlling the laser from your phone. Set it to Autoplay or take a break and use the buttons to direct the laser yourself. See the video below for build instructions and of course their cat, [Pepper], looking like a Flamenco dancer chasing the light.

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Metal 3D Printing: Insta-Layers

May 29, 2017 by Michael Uttmark 19 Comments

Selective Metal Sintering is cool but slow. Fear not, a technology that was initially developed to smooth and pattern laser beams is here to save the day, according to a new paper by Lawrence Livermore researchers.

In a paper titled “Diode-based additive manufacturing of metals using an optically-addressable light valve,” the researchers lay out a procedure for using an array of high-powered laser diodes among other things to print a whole layer of metal from powdered metal at one time. No more forward and backward, left and right. Just one bright flash and you’re done. Naturally, the technology is still in its infancy, but huge 3D printed metallic parts are something we’ve always hoped for.

According to [Matthews], the first author of the paper, the mojo of the process comes from a customized laser modulator: the Optically Addressable Light Valve which functions similarly to liquid crystal-based projectors but can handle the high energies associated with powerful lasers. There’s more information straight from the paper’s authors in this phys.org interview.

While it’s true that now is the time for direct metal 3D printing, it appears that for the time being the average hacker is stuck with alternative methods for printing metal. While it’s not the same, pewter casting with PLA might suffice.

Thanks to [Kevin] for sending this in!