Fire Extinguishers, Optical Density Ratings And Safely Using Home Lasers

Ski goggle type laser safety lenses may look dorky, but they leave no gaps and fit around glasses. (Credit: FauxHammer, YouTube)
Ski goggle type laser safety lenses may look dorky, but they leave no gaps and fit around glasses. (Credit: FauxHammer, YouTube)

After [Ross] from FauxHammer miniature model fame got lured into reviewing laser engravers and similar via the Bambu Lab H2D’s laser module, he found himself getting slightly nervous about the whole ‘safety’ aspect of these lasers. After all, lasers can not only light stuff on fire, but it’s a well-known fact that even reflected laser light can be sufficient to cause permanent damage to your retinas. Or worse.

Since your eyes generally do not regenerate, it makes sense to get caught up on laser safety before turning on one of those plentiful-and-increasingly-affordable home laser systems for engraving and/or cutting.

While the issue of stuff catching on fire is readily solved by having a good CO2 extinguisher – and plan B options – at the ready, for safety glasses it’s significantly more complex. There’s not just the issue of finding glasses that block the wavelength of the laser system that you are using, but also with the right optical density (OD) rating. Every mm of the safety lens material can attenuate a certain amount of laser light at the given wavelength, so the OD rating of your laser safety goggles need to match the laser’s power output level, or you might be living with a false sense of security.

Finally, there is the issue of the smoke and fumes produced by these lasers as they obliterate the target material. Much of what is in this smoke you do not want to breathe in, even ignoring long-term dust and VOC exposure issues, so having a solid fume extraction setup and PPE as necessary are absolute necessities. As [Ross] puts it, you don’t want to breathe in the smell of regret today, for your future self to reflect on a decade from now.

Work safe, work smart, don’t become the subject of a laser safety PSA.

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Getting A Laser Eye Injury And How To Avoid It

Most people love lasers, because they can make cats chase, read music from a shiny disc, etch and cut materials, and be very shiny in Hollywood blockbusters, even when their presence makes zero sense. That said, lasers are also extremely dangerous, as their highly focused nature and wide range of power levels can leave a person dazzled, blinded or dead from direct and indirect exposure. A lapse in laser safety was how [Phil Broughton] ended up with part of his retina forever marked, as he describes his adventures with an overly enthusiastic laser company sales person.

Quanta Ray PRO350 with frequency doubling, emitting a 532nm beam – Sales brochure image from Quanta Ray, unknown date
Quanta Ray PRO350 with frequency doubling, emitting a 532 nm beam – Sales brochure image from Quanta Ray, unknown date

It didn’t take much, just this sales person who made a really poor decision while trying to please some customers and nearly ended with multiple adults, a local school, pilots at a nearby airfield getting their retinas blasted out due to an absolutely harebrained idea to use a fairly high-powered Quanta-Ray Nd:YAG laser on reflective surfaces in the open.

This was in 1999, and fortunately [Phil] only suffered some fairly minor damage to his retina from the laser beam reflection. What happened to the customers (who wore argon laser safety glasses) or the sales critter (who left soon after) is not described, but both may have received some bad news when they had their eyes checked shortly after at the ophthalmologist.

These kind of stories are a stark reminder that laser safety is not optional. Lasers producing a visible (400 – 700 nm) wavelength above Class 2 should only be operated in a fully secured environment, with safety glasses for the appropriate laser wavelength. Class 2 lasers producing a non-visible wavelength can cause permanent damage because the blink reflex of the eye does not offer any protection here.

As even some dodgy laser pointers are being (illegally) sold online are actually Class 2, this should make it clear that laser eye injury can happen to anyone, and it only takes a second to change someone’s life forever.

The laser driver's internals, showing the custom PCB, the PSU, connectors and the interlocks.

Laser Driver Design Keeps Safety First

[Les] from [Les’ Lab] has designed a driver for laser diodes up to 10 watts, and decided to show us how it operates, tells us what we should keep in mind when designing such a driver, and talks about laser safety in general. This design is an adjustable current regulator based on the LM350A, able to provide up to 10 watts of power at about 2 volts – which is what his diode needs. Such obscure requirements aren’t easily fulfilled by commonly available PSUs, which is why a custom design was called for.

He tells us how he approached improving stability of the current regulation circuit, the PCB design requirements, and planning user interface for such a driver. However, that’s just part of the battle – regulating the current properly is important, but reducing the potential for accidental injuries even more so. Thus, he talks extensively about designing the driver circuit with safety in mind – using various kinds of interlocks, like a latching relay circuit to prevent it from powering up as soon as power is applied.

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