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Laser-Burning.Pdf 1 . There are a variety of laser technologies available . Most commonly used for laser engraving/burning applications (hobby) . Semiconductor Lasers (diode lasers) . CO2 (Gas) Lasers . Laser output is specified in power and wavelength (color) . Semiconductor Lasers typically operate in visible light range ~380 – 700 nm . CO2 lasers typically operate in infrared (>800 nm) range . Generally speaking, shorter wavelength lasers output more power per area . Semiconductor lasers generally do not focus quite as well as CO2 or other gas lasers . Semiconductor lasers are generally less expensive . Moving the laser beam . Most common methods are stepper motors or servos . Servos are typically more precise, but also bigger and more expensive than stepper motors 2 The continuous or average power required for some uses: Power Use 1–5 mW Laser pointers 5 mW CD-ROM drive 5–10 mW DVD player or DVD-ROM drive 100 mW High-speed CD-RW burner 250 mW Consumer 16× DVD-R burner Burning through a jewel case including disc within 4 seconds[82] 400 mW DVD 24× dual-layer recording[83] 1 W Green laser in Holographic Versatile Disc prototype development Output of the majority of commercially available solid-state lasers used for micro 1–20 W machining [84] 30–100 W Typical sealed CO2 surgical lasers 100–3000 W Typical sealed CO2 lasers used in industrial laser cutting 3 • 15 W • 65 x 65 cm working area (Approx 25 x 25 inches) • 3 Stepper Motors • 1 controls X direction • 2 control Y direction • 0.1 mm resolution • 450 nm Semiconductor Laser • Connected computer needed to run I don’t recommend this seller • Assembly not well documented • Missing a few screws • Wrong wall plug (EU style) • Poor support • Dangerous Software Many other sellers offer the same (or similar) setups 4 5 Important to keep pulley belt taught 6 . Other Accessories or useful features . Cylinder Rotation . Rotate in place of Y-axis movement . Offline operation . Download engraving instructions to dedicated module so that you don’t need to connect a computer . Z-Axis Movement . Router Spindle . Small motors are available that are compatible with the laser modules Router spindle • https://www.aliexpress.com/item/4000195000426.html?spm=2114.12010612.81 48356.1.2f2777e4xF0Fte • https://www.aliexpress.com/item/4000636088934.html?spm=2114.12010612.81 48356.30.772f645dyDNuyP 7 . Engraving Software – load pictures and generate control codes for the laser: . LaserEngraver . Came with hardware . Easy to Use . Has some good features . DANGEROUS FAILURES – DO NOT USE . LaserGRBL . Open Source software . Made some minor modifications to configuration . Drawing and Composition . Visio, Paint . Microsoft Software used for drawing and composition . Many other options available . GIMP • LaserEngraver software failed, twice, during the first few longer burn times (> 4 hours) • Once with the laser off – no way to restart from point of failure, couldn’t recover the piece • Once with the laser on – burned a fairly deep hole in the piece before I noticed/turned off • I use LaserGRBL for burning • Other commercial or open source options available • I use Visio, Paint, and the occasional other program for creating images 8 Firmware is the controller software that resides on the board to control the laser and the motion of the laser head . There are several different firmware packages commonly in use. The first 3 are derived from the same origin (GRBL) and are generally supported by most open laser engraving packages: . GRBL – GRBL was originally developed for CNC machines, but many laser controllers use a modified version. Starting with version 1.1 (latest version is 1.1h), GRBL has some explicit support for laser mode operation. Marlin – also a derivative of GRBL, Marlin has seen enhancements aimed at the 3D printing community, but it is also used for lasers . Smoothieware – a GRBL derivative for use with Smoothieboard 32 bit controller . BenBox – proprietary engraving software and firmware. • Generally, don’t need to worry about firmware except when looking for 3rd party engraving software that is compatible 9 G0 X[left] Y[bottom] M3 S1 G1 X[right] F[jogspeed] G1 Y[top] G1 X[left] G1 Y[bottom] M5 G0 X0 Y0 Added 2 buttons • Toggle laser on/off at low power for positioning • Walk the bounding box of the image to verify positioning 10 • LaserGRBL uses Spindle Speed to set power output • This is an arbitrary value used to designate the max power available • Laser-mode is a new feature added in v1.1 • Allows some optimization of motion steps for laser vs CNC • Configuration Settings for GRBL/Firmware • LaserGRBL is adapted from CNC Software • It uses “Spindle Speed” to, instead, control Laser Power • This setting establishes a value for the highest power output • Other power settings are scaled from this value, e.g. • 500 = 50% power • 300 = 30% power • Default value was 255. I changed to 1000 to make it easier to think about relative power, but 255 is the actual number of discrete values that can physically be controlled on the device. • After changing a setting, click “Write” to commit to the controller 11 . It can burn down your house/shop . Supervise . Burning process can take a long time . Medium sized (12-14 inches) platter could take 10-15 hours . It is possible for the process to fail/get stuck with the laser “on” . Choose an area free of combustibles . The laser is burning the surface . Good ventilation is also important – it will generate a lot of smoke . Make sure computer will not go to sleep . If computer sleeps, software may shut down with laser “on” . It can damage your eyes . Wear Eye Protection . Blue, Green color (~500 nm) are most dangerous, but all wavelengths can damage eyes at the power levels we’re using, even reflected . Eye protection should be specific to the wavelength of the laser in use . Never look directly into a laser . It’s generally mounted pointing down, but don’t let it point at you I generally never look, even in the direction of the laser, without eye protection 12 Lasers are usually labeled with a safety class number, which identifies how dangerous the laser is: . Class 1 is inherently safe, usually because the light is contained in an enclosure, for example in CD players. Class 2 is safe during normal use; the blink reflex of the eye will prevent damage. Usually up to 1 mW power, for example laser pointers. Class 3R (formerly IIIa) lasers are usually up to 5 mW and involve a small risk of eye damage within the time of the blink reflex. Staring into such a beam for several seconds is likely to cause damage to a spot on the retina. Class 3B can cause immediate eye damage upon exposure. Class 4 lasers can burn skin, and in some cases, even scattered light can cause eye and/or skin damage. Many hobby, industrial and scientific lasers are in this class. • Some risk is inherent even with Class 3R, with power only up to 5 mw. • Lowest power used for engraving (on soft materials) will be, at least, 1000 mw • My 15W laser, at it’s lowest setting (used only for positioning), is still nearly 60 mw 13 . Choose/Compose Artwork . Original composition . Picture with masking . Duplicate and Rotate . Higher power will likely cause some overburn . Loss of detail . Smoothens rough edges . Know your laser . Experiment with different line widths, power, engraving speed . Test for accuracy, square . Test on different surfaces/types of wood • It can theoretically engrave greyscale by modulating the power and thereby engrave photos • I’ve only tried a few small experiments, with poor results, and haven’t pursued this further 14 Find or create an image you want to use 15 Create a mask from a square the size of the image (crop to size if needed) and a circle the size of the bowl, then “subtract” 16 • Overlay the mask on top of the image (fill mask with white rather than the blue, shown) • Overlay a circle the size of the cored area • Saves time by not burning the cored area • Save as JPG file • Visio defaults to output at 120 dpi • Laser engraves at 254 dpi • Visio image should be 254 / 120 = 2.16 times the size of the desired image 17 • Start with a properly sized circle for the size of your bowl/platter • Create drawing or image your want to repeat around the rim and position at 12:00 and 6:00 18 • Group and duplicate the image • Rotate to appropriate angle • 90 degrees for 4 images • Multiples of 45 degrees for 8 images • Multiples of 30 degrees for 12 images • etc 19 • Center copied groups on the original to complete layout 20 Speed (mm/minute) 200 Max Power (S-Max) 1000 Marble (Image size is approx 1.5 inches square) In LaserGRBL, you can vary speed of the laser head movement, and the power output of the laser. In this case, “1000” is 100% power or 15W 21 Speed (mm/minute) 200 Speed (mm/minute) 200 Max Power (S-Max) 1000 Max Power (S-Max) 1000 Marble Poplar (Image size is approx 1.5 inches square) In LaserGRBL, you can vary speed of the laser head movement, and the power output of the laser. In this case, “1000” is 100% power or 15W 22 Speed (mm/minute) 800 Speed (mm/minute) 800 Speed (mm/minute) 800 Max Power (S-Max) 300 Max Power (S-Max) 225 Max Power (S-Max) 150 Experiment to find what values work best for your laser and target material 23 Speed (mm/minute) 400 Speed (mm/minute) 1800 Max Power (S-Max) 150 Max Power (S-Max) 300 24 Fixed focus laser should have a positioning block for optimal distance Variable focus will allow you to adjust via lens 25 • Load image file • Flip side-to-side (image will be L-R reversed) • Choose power (S-MAX), Engraving Speed • Resize if needed • Set offset from center (-1/2 X dimension and -1/2 Y dimension) • I haven’t experimented much with re-sizing through LaserGRBL.
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