80 watt laser engraver: Difference between revisions

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80 watt laser engraver (view source)

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super rough notes, don't even look at me pls
 




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*engraving and cutting can be put in same file, when you get them into lasercut select cuts and push them to a later layer (select line, select layer colour)
*engraving and cutting can be put in same file, when you get them into lasercut select cuts and push them to a later layer (select line, select layer colour)
*think about cut order, if it matters push cuts to different layers, e.g. shark with eye cut out, cut out eye first then shark, otherwise shark could fall away or move before the eye has been cut
*think about cut order, if it matters push cuts to different layers, e.g. shark with eye cut out, cut out eye first then shark, otherwise shark could fall away or move before the eye has been cut
*make sure the exhaust fan is outside outside, plug it in and cover up the gap in the bay door
*laser does not cut at lower power levels (TBD) ~ 25 - 30%. Head moves properly but no cutting (although it still may be firing)
*laser does not cut at lower power levels (TBD) ~ 25 - 30%. Head moves properly but no cutting (although it still may be firing)
*after long cuts LaserCut5.1 often looses contact with the laser, file->reconnect will often restore connectivity, if not: save your project, close LaserCut5.1 unplug the usb connector to the laser, reconnect it, restart LaserCut5.1, open your saved project.  
*after long cuts LaserCut5.1 often looses contact with the laser, file->reconnect will often restore connectivity, if not: save your project, close LaserCut5.1 unplug the usb connector to the laser, reconnect it, restart LaserCut5.1, open your saved project.  
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== Using the machine ==
== Using the machine ==
regurgitate the above here
3 Procedures must be followed as prescribed
# Safe Power Up Procedure to be performed whenever the machine needs to be turned on
# Pre-Cut Check to be performed before the first cut and after any break between cuts, don't assume the machine is as you left it.
# Safe Power Down Procedure


=== Powering up the machine ===
=== Safe Power Up Procedure ===
With very few exceptions, the same order of operations should always be maintained for safe proper operation.  Failing to enable a portion of the cooling system will damage the laser.
With very few exceptions, the same order of operations should always be maintained for safe proper operation.  Failing to enable a portion of the cooling system will damage the laser.
# Open cutting area and remove any objects from the working bed.
# Verify the cooling tank has enough water.  
# Plug in circulation pump to a 110v circuit. (currently does not power on with chiller),
# Turn on the circulation pump, sometimes it's unplugged from the black power bar, sometimes the black power bar is turned off, plug it into the black power bar ONLY, and ensure the power bar is on.
# Power on 120-240 voltage converter (box on trolley with green light-up switch).
# Power on 120-240 voltage converter (box on trolley with green light-up switch).
#* Verify that power is applied to the chiller and air pump.  These are 220v appliances and need to be plugged directly into the voltage converter.
#* Verify that power is applied to the chiller and air pump.  These are 220v appliances and need to be plugged directly into the voltage converter. The display panel on the chiller should light up, and the hanging pump should now be vibrating.  
# Set up ventilation fan outdoors, leave unplugged but switch unit on. 
#* During colder temperatures only run exhaust while cutting is taking place.
# Activate power to laser cutter from switch on back of unit.
# Activate power to laser cutter from switch on back of unit.
# Deactivate E-stop with a twisting motion, and power on laser with key switch on front panel. The key had 3 positions, rotating clockwise the positions are off, off, on.  
# Deactivate E-stop with a twisting motion, and power on laser with key switch on front panel. The key had 3 positions, rotating clockwise the positions are off, off, on.  


The laser is now active and ready to accept instructions from the laptop.
The laser is now active and ready to accept instructions from the computer.
'''Warning!'''  The laser is a stand-alone unit and ''can move/execute programs/fire the laser with the laptop disconnected.''


=== Pre-Cut Check ===
# Ensure the circulation pump is running
# Ensure the air pump is running
# Ensure the exhaust fan is on (this one will frequently be turned off between cuts so always check it)
# Verify the work area is free of obstructions
# With a hand over the E-Stop, run a test to see if the cut envelope will cause the head to collide with any obstructions (weights, sides) Do not allow the head to collide with ANYTHING when in doubt hit the E-STOP and reset with the workpeice re-positioned or the obstructions removed, in extreme cases you may have to modify or abandon the cut.
=== Shutting down the machine ===
Following the same steps in reverse order will help ensure the machine is left in a safe mode.
# Activate E-stop to render the work-area safe. 
# Clean out remnants from the cutting area.
# Turn off power from the key switch, this will turn off the work-light.
# Turn off the power switch at the back of the laser.
# Deactivate the exhaust fan
# Power down voltage converter (green switch)
# Unplug circulation pump




=== Focusing the Laser ===
=== Focusing the Laser ===
[[File:LaserPath.png|300px|thumb|right|Figure 1. laser path visualization]]
[[File:LaserPath.png|300px|thumb|right|Figure 1. laser path visualization]]
Use the Z+ and Z- buttons to raise and lower the table.  There are a few considerations when selecting a focal depth:<br>
'''Warning!''' The Z+ and Z- keys work independently of any software control.  It is possible to change the z height to values that would crash the the workpiece into laser head, particularly while the laser is operational.  Be very cognizant of where everything is while you are moving the table!
Depending on the thickness of the material and whether you are cutting or engraving you will need to set an appropriate focal distance.  The beam does not come out of the lens parallel, but in fact is conically shaped. See: Figure 1.
Depending on the thickness of the material and whether you are cutting or engraving you will need to set an appropriate focal distance.  The beam does not come out of the lens parallel, but in fact is conically shaped. See: Figure 1.


==== Focal Depth: ====
[[File:LaserFocus.png|300px|thumb|right|Figure 2. Focal Depth: Bottom shows resultant cut shape.]]
[[File:LaserFocus.png|300px|thumb|right|Figure 2. Focal Depth: Bottom shows resultant cut shape.]]
For engraving, you want the focal point right on the surface for the fastest/most efficient results.
For engraving, you want the focal point right on the surface for the fastest/most efficient results.


For cutting, you want the focal point to be near the midpoint of the thickness of the material so that it makes the straightest edges on the cuts.  See Figure 2.
For cutting, you want the focal point to be near the midpoint of the thickness of the material so that it makes the straightest edges on the cuts.  See Figure 2.<br>
----


=== Load the program! ===
The LaserCut5.1 software is a bit tricky.
See:  Sample Workflow (below)


=== Cut the loaded program! ===
Once a cut program has been loaded to the laser from the LaserCut5.1 software, the laser head should be aligned with the workpiece.
# Select the project loaded to the laser on the LCD menu, It is the text on the top right of the main menu. 
#* Multiple files can be loaded on the machine.
#* The file should be 'selected' (highlighted black box over the name).  If not, press the ESC key to reload the main menu and the file will be selected.
#* Pressing the left/right key should cycle through the loaded files.
# Jog the laser head to the intended origin with the arrow keys
#* In order for the jog keys to work, nothing can be selected on the menu, hit ESC so that no text is highlighted on the screen.  When done, to return to a working mode ESC must be pressed again to select the file.
#* This is the same origin as set in the loaded file; it can be anywhere on the table.  Common selections are 'top left' of the piece or 'centre' of the workpiece.
# Ensure the workpiece is aligned by using the 'Test' function.
#* The machine is unaware of the head's location, and will happily destroy itself if bad instructions are given.
#* Be ready to shut down the machine if the head appears to be going out of bounds.
#* Press the 'Test' key to have the laser head draw a bounding box around the outer limits of your project.
# Once everything is aligned, press the 'Start/Pause' key to start the cut.
#* To pause the cut, press 'Start/Pause' again.  One more press will resume where the program left off.
#* To abort the current program (something is horribly wrong), press the stop key.  This will abort the program and it will have to be restarted from the start.  The head should home back to the origin from before the program was started.




== Cut Guidelines ==
These charts are intended to give you a starting range, from which you must dial in with testing, use scrap that is the same material and thickness as your intended work piece and use a small test pattern( e.g Laser Coin) to fine tune your desired results


=== Shutting down the machine ===
'''WARNING!'''  Above all other warnings, never, ever, EVER cut or engrave anything with the word vinyl, pvc, polyvinyl chloride, etc in it's name.  It will release forms of chlorine gas (incredibly toxic and caustic) which will quickly degrade the components in the machine.  Even with the exhaust running, the 'smoke' from cutting pvc can permanently damage the machine and your face.  DON'T DO IT!
Following the same steps in reverse order will help ensure the machine is left in a safe mode.
# Activate E-stop to render the work-area safe.   
# Clean out remnants from the cutting area.
# Turn off power from the key switch, this will turn off the work-light.
# Deactivate/put away exhaust fan
# Power down voltage converter (green switch)
# Unplug circulation pump
# Turn off power to back of unit
 
== Cut Guidelines ==
These charts are intended to give you a starting range, from which you must dial in with testing, use scrap that is the same material and thickness as your intended work piece and use a small test pattern(laser coin) to fine tune your desired results


charts of material x thickness
charts of material x thickness


Acrylic Cut Etch
{| border="1"
2mm speed 5-10 power 100
!colspan="5"|Acrylic
6mm speed ?   power ?
|-
 
|rowspan="2"|Thickness
|colspan="2"|Etch
|colspan="2"|Cut
|-
|Speed
|Power
|Speed
|Power
|-
|2mm
|?
|?
|?
|?
|-
|6mm
|?
|?
|?
|?
|}


{| border="1"
!colspan="5"|?
|-
|rowspan="2"|Thickness
|colspan="2"|Etch
|colspan="2"|Cut
|-
|Speed
|Power
|Speed
|Power
|-
|2mm
|?
|?
|?
|?
|-
|6mm
|?
|?
|?
|?
|}


{| border="1"
!colspan="5"|?
|-
|rowspan="2"|Thickness
|colspan="2"|Etch
|colspan="2"|Cut
|-
|Speed
|Power
|Speed
|Power
|-
|2mm
|?
|?
|?
|?
|-
|6mm
|?
|?
|?
|?
|}


== Sample Workflow ==
== Sample Workflow ==
This is *a* workflow that has been working consistently, there are other tools and processes that will work but to get started  
This is *a* workflow that has been working consistently, there are other tools and processes that will work but to get started  


First, ensure SketchUp is installed and working correctly. Then install the export to DXF plugin (http://www.guitar-list.com/files/skp_to_dxf.rbz)


Process notes
Starting from scratch:
 
# Start a new SketchUp project and select a metric mm template
*google sketchup -> dxf via http://www.guitar-list.com/files/skp_to_dxf.rbz
# Draw your model as 2d line work on the XY plane, Tip: use the overhead camera view.  
*take file to laser laptop
# Select the part of your model to be exported to DXF (can select all)
*open dxf in autocad save as 2004 dxf
# Use the plugin to create the DXF file, select mm as the export unit and export as lines
*import in lasercut5.1
# Transfer file to laser workstation
*download button
# Open dxf in autocad save as 2004 dxf
*download current
# Follow the startup procedures as above
*do setup tests for function, focus,  
# Follow the pre-cut procedures as above
*use test to setup test piece
# Test cut/engrave settings on a sample of the target work material (e.g. do Laser Coin Test)
*verify cut/engrave speed and power settings
# Import in lasercut5.1
*use test to setup work piece
# Divide the project into appropriate layers, first layer should be engraving, second layer should be for internal cuts and a final layer for the outer cut
*cut
# Set engrave/cut settings for each layer
# Set laser origin (Laser -> set origin, top left)
# Hit the download button at the bottom of the panel on the right
# Hit delete all
# Hit download current, this can take some time if the project is complex, if it takes too long you may want to break the cut up into smaller chunks.
# Follow the pre-cut procedures as above
# Hit start
# Follow the safe shutdown procedures as above




Codohundo
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