Fun With A 200-kW Fiber Laser

December 2, 2019 by Dan Maloney 23 Comments

We’ve all heard the “Do not stare into laser with remaining eye” joke. It’s funny because it’s true, as pretty much any laser a hobbyist can easily come by can cause permanent damage to eyes unless the proper precautions are taken. But a fiber laser with 200kW peak power is in another hazard class entirely.

Granted, outsized power ratings like this are a bit misleading, based as they are on femtosecond-long pulses. And to be sure, the fiber laser that [Marco Reps] tears down in the video below was as harmless as a kitten when he got it, thanks to its output optics having been unceremoniously shorn from the amplifier by its former owner. Reattaching the output and splicing the fiber would be necessary to get the laser lasing again, but [Marco] had other priorities in mind. He wanted to understand the operation of a fiber laser, but the tangle of fibers on two separate levels inside the chassis was somewhat inscrutable. The coils of fiber wrapped around the aluminum drums inside the chassis turned out to be the amplifier; fed by a semiconductor seed laser, the light pulse travels through the ytterbium-doped fiber of the two-stage amplifier, which is the active gain medium where stimulated emission, and therefore amplification, occurs.

With a little reverse engineering and the help of an online manual, he was able to understand the laser’s operation. A laser company helped him splice the optics back together – seeing the splicing rig in action is worth the price of admission alone – and the unit seems to be in more or less working order at this point. Normally the most powerful laser we see around here are the CO₂ lasers in those cheap Chinese laser cutters, so we’re looking forward to learning more about fiber lasers.

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Turning OLEDs And Acrylic Into Faux Nixie Tubes

November 26, 2019 by Dan Maloney 8 Comments

Love ’em or hate ’em, Nixies and the retro clocks they adorn are here to stay. At least until the world’s stock of surplus Soviet tubes is finally depleted, that is. The glow discharge tubes were last mass manufactured in the 1980s, and while they’re not too hard to get a hold of yet, they will be eventually. And what better way to get ready for that dreaded day than by rolling your own OLED faux Nixie tubes?

Granted, [Derek]’s faux Nixies, appropriately dubbed “Fixies,” require just a touch of willing suspension of disbelief. We’ve never see Nixies with tiny jam jars as envelopes, so that’s probably the first giveaway. But looking past that, the innards of these fake displays do a pretty convincing job of imitating the texture of the real thing.

The numbers themselves are displayed on a 128×64 white OLED display using a Nixie-like True Type font. An orange acrylic filter in front of the display gives it that warm amber Nixie glow, with laser etchings mimicking both the fine hexagonal anode grid and the ghostly cathodes of the non-illuminated numerals. The tubes looked convincing enough that a clock was in order, and after sorting through an I2C bottleneck with the help of a multiplexer, [Derek] had a pretty decent faux-Nixie clock, complete with a solenoid-actuated mechanical gong. The double-digit display for the seconds will no doubt cause some consternation among Nixie purists, but that’s probably part of the fun.

Of course, just because Nixies aren’t being mass-produced today doesn’t mean you can’t get new ones. You just have to be willing to pay for them, and [Dalibor Farný] will gladly set you up with his handmade artisanal Nixies, or even a clock kit using them.

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Hackaday Links: November 17, 2019

November 17, 2019 by Dan Maloney 8 Comments

Friday, November 15, 2019 – PASADENA. The 2019 Hackaday Superconference is getting into high gear as I write this. Sitting in the Supplyframe HQ outside the registration desk is endlessly entertaining, as attendees pour in and get their swag bags and badges. It’s like watching a parade of luminaries from the hardware hacking world, and everyone looks like they came ready to work. The workshops are starting, the SMD soldering challenge is underway, and every nook and cranny seems to have someone hunched over the amazing Hackaday Superconference badge, trying to turn it into something even more amazing. The talks start on Saturday, and if you’re not one of the lucky hundreds here this weekend, make sure you tune into the livestream so you don’t miss any of the action.

The day when the average person is able to shoot something out of the sky with a laser is apparently here. Pablo, who lives in Argentina, has beeing keeping tabs on the mass protests going on in neighboring Chile. Huge crowds have been gathering regularly over the last few weeks to protest inequality. The crowd gathered in the capital city of Santiago on Wednesday night took issue with the sudden appearance of a police UAV overhead. In an impressive feat of cooperation, they trained 40 to 50 green laser pointers on the offending drone. The videos showing the green beams lancing through the air are quite amazing, and even more amazing is the fact that the drone was apparently downed by the lasers. Whether it was blinding the operator through the FPV camera or if the accumulated heat of dozens of lasers caused some kind of damage to the drone is hard to say, and we’d guess that the drone was not treated too kindly by the protestors when it landed in the midsts, so there’s likely not much left of the craft to do a forensic analysis, which is a pity. We will note that the protestors also trained their lasers on a police helicopter, an act that’s extremely dangerous to the human pilots which we can’t condone.

In news that should shock literally nobody, Chris Petrich reports that there’s a pretty good chance the DS18B20 temperature sensor chips you have in your parts bin are counterfeits. Almost all of the 500 sensors he purchased from two dozen vendors on eBay tested as fakes. His Github readme has an extensive list that lumps the counterfeits into four categories of fake-ness, with issues ranging from inaccurate temperature offsets to sensors without EEPROM that don’t work with parasitic power. What’s worse, a lot of the fakes test almost-sorta like authentic chips, meaning that they may work in your design, but that you’re clearly not getting what you paid for. The short story to telling real chips from the fakes is that Maxim chips have laser-etched markings, while the imposters sport printed numbers. If you need the real deal, Chris suggests sticking with reputable suppliers with validated supply chains. Caveat emptor.

A few weeks back we posted a link to the NXP Homebrew RF Design Challenge, which tasked participants to build something cool with NXP’s new LDMOS RF power transistors. The three winners of the challenge were just announced, and we’re proud to see that Razvan’s wonderfully engineered broadband RF power amp, which we recently featured, won second place. First place went to Jim Veatch for another broadband amp that can be built for $80 using an off-the-shelf CPU heatsink for thermal management. Third prize was awarded to a team lead by Weston Braun, which came up with a switch-mode RF amp for the plasma cavity for micro-thrusters for CubeSats, adorably named the Pocket Rocket. We’ve featured similar thrusters recently, and we’ll be doing a Hack Chat on the topic in December. Congratulations to the winners for their excellent designs.

Making Models With Lasers

November 16, 2019 by Bryan Cockfield 4 Comments

Good design starts with a good idea, and being able to flesh that idea out with a model. In the electronics world, we would build a model on a breadboard before soldering everything together. In much the same way that the industrial designer [Eric Strebel] makes models of his creations before creating the final version. In his latest video, he demonstrates the use of a CO2 laser for model making.

While this video could be considered a primer for using a laser cutter, watching some of the fine detail work that [Eric] employs is interesting in the way that watching any master craftsman is. He builds several cubes out of various materials, demonstrating the operation of the laser cutter and showing how best to assemble the “models”. [Eric] starts with acrylic before moving to wood, cardboard, and finally his preferred material: foam core. The final model has beveled edges and an interior cylinder, demonstrating many “tricks of the trade” of model building.

Of course, you may wish to build models of more complex objects than cubes. If you have never had the opportunity to use a laser cutter, you will quickly realize how much simpler the design process is with high-quality tools like this one. It doesn’t hurt to have [Eric]’s experience and mastery of industrial design to help out, either.

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Laser Toy Keeps Cats Entertained

October 26, 2019 by Lewin Day 13 Comments

Cats are among the most popular domesticated creatures, and their penchant for chasing laser pointers is well known. With a pair of felines of his own to look after, [Tobi] set about making a device to help keep them entertained.

The aim of the device is to automate the motion of a laser pointer to make playing with the cats a hands-free operation. A pan-tilt servo mechanism has a low-power red laser pointer fitted, and the assembly is hooked up to a NodeMCU microcontroller. Based on the ESP8266, it allows the system to be controlled remotely over WiFi. Various sweeps can be automatically commanded from a smartphone, or the servo position can be controlled manually.

Test footage confirms that [Tobi’s] pets do indeed find the device to be worthy prey. It’s a popular build for cat lovers, and readily achievable with off-the-shelf parts. If you’ve built your own hardware to keep these proud hunters out of trouble, be sure to hit up the tip line.

Building A Laser Head With High Speed, High Resolution

October 22, 2019 by Lewin Day 9 Comments

A test exposure on cyanotype paper shows off the prototype’s resolution, around 100 microns.

Typically, when it comes to scanning a laser, it’s done with galvos or a rotating mirror assembly. However, these methods can be slow and cumbersome, or restricted due to existing patents. [Rick] aimed to find an alternative solution with the Hexastorm project, using a rotating prism to build a high speed, high resolution laser head.

The project currently uses a Beaglebone for the brains, with a polygon motor sourced from a photocopier used to rotate the prism at over 20,000 rpm. The project aims to be a proof of concept for rotating prism technology, which can then be adapted to specific tasks. With the promise of high speed and high resolution, the system could be used in fields as diverse as PCB manufacture, 3D resin printing, and even virtual reality displays. [Rick] explores these potential markets in a pitch deck, comparing to existing solutions in the marketplace.

If you’re interested in high performance optical systems, [Rick]’s work makes compelling reading. It’s not the first time we’ve explored cutting edge laser hacks, either. Video after the break. Continue reading “Building A Laser Head With High Speed, High Resolution” →

Another Way To Make PCBs At Home

August 27, 2019 by Bryan Cockfield 32 Comments

One of the more popular ways of rolling out your own custom PCB is to simply create the model in your CAD program of choice and send it off to a board manufacturer who will take care of the dirty work for you. This way there is no need to deal with things like chemicals, copper dust, or maintaining expensive tools. A middle ground between the board manufacturer and a home etching system though might be what [igorfonseca83] has been doing: using an inexpensive laser engraver to make PCBs for him.

A laser engraver is basically a low-power laser CNC machine that’s just slightly too weak to cut most things that would typically go in a laser cutter. It turns out that the 10W system is the perfect amount of energy to remove a mask from a standard PCB blank, though. This in effect takes the place of the printer in the old toner transfer method, and the copper still has to be dissolved in a chemical solution, but the results are a lot more robust than trying to modify a printer for this task.

If you aren’t familiar with the days of yore when homebrew PCBs involved a standard desktop printer, many people still use this method, although the results can be mixed based on printer reliability. If you want to skip the middleman, and the need for a chemical bath, a more powerful laser actually can cut the traces for you, too.

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