Laser engravers?
5 years ago
Weird question but it's more related to my side business 😂 I'm looking for a laser engraver/cutter that can handle approx 2mm clear acrylic; it needs to be able to cut multiple 1.5mm diameter holes through the plastic.
Does anyone have experience with, or recommendations? I'd love for it to have a larger working area (8 inches tall x 12-20 inches long) and am happy to invest a little more into the right product.
Does anyone have experience with, or recommendations? I'd love for it to have a larger working area (8 inches tall x 12-20 inches long) and am happy to invest a little more into the right product.
Obviously any unit that's lacking basic safety features like a full enclosure with door interlocks etc should be avoided.
Air assist can be a really nice feature to have, as it will help clear the smoke around the beam path so that it doesn't obscure the laser and mess up the cut.
Getting a unit with a built-in camera can be really useful for positioning the cut path on the material.
For just 2mm acrylic you should be able to get away with a pretty cheap unit, it won't require that much power to cut through (depending on the exact material of course, cuttability can be highly variable between different colors and types of acrylic). I don't have any specific model recommendations though.
The common 5.5w blue laser cutters/engravers pas right through clear acrylics (and even some colored ones.)
A cheapie "K40" style laser can handle 12" x 8" sheets, especially if you get an air assist nozzle. They're a bit big (mine is small-coffee-table sized).
The specific one I bought isn't available anymore but the basic design is super common so if you get one that looks kinda like it it'll be close enough that most if not all of the info online can work with it: https://www.amazon.com/gp/product/B.....UTF8&psc=1 (honestly just search "k40 laser" and get the cheapest one with okay reviews)
The default lens and holder... work. I'd suggest replacing them because the holder doesn't do air assist (but hold on to them as a backup).
Here's the holder I bought with air assist: https://www.amazon.com/gp/product/B.....UTF8&psc=1
It doesn't work with the smaller lens the K40s typically come with so I bought one of these: https://www.amazon.com/gp/product/B.....UTF8&psc=1
For the actual air pump anything works really but I bought one of these: https://www.amazon.com/gp/product/B.....UTF8&psc=1
I would suggest getting a power strip to run all the extra stuff off of. The K40 includes a couple of electrical sockets for the extras but the wiring is mediocre and tends to starve the laser if you have too much running off it. I tend to stick with just the fan and water pump.
The laser REQUIRES water cooling. Mine came with a cheapo aquarium pump that does well enough. I'd recommend getting a couple buckets at the Home Depot (because I work at one) and when you fill them with water add a splash of bleach to keep stuff from growing in it. When you run it you can add ice to the bucket, but I would recommend getting a water chiller to keep the water a consistent temperature. There have been a few things I've etched that were quite obvious when I added ice to the bucket. Most of the cheaper chillers don't come with pumps or tubing so you'll also probably need to pick up some adapters and tubing at the Depot when you get your buckets.
The default work piece tray sucks. I don't have any recommendations for a replacement as I still need to get one, but at least with the tray you can remove that holding bracket thing in the middle so it's flat(ish).
The K40 also comes with a really shitty exhaust fan that only kinda fits. It's terrible, but once you plug up the holes it works okayish. Replacing that with something custom made is common, but due to the weird shape of the exhaust it's kinda tricky.
To control it, you'll want the Inkscape SVG program, and a program called "K40 Whisperer" that is way better than the suspect software they give you (honestly I just threw the USB stick they gave with it in the trash).
Before you run it you'll want to align the mirrors: https://k40.se/lens-mirrors/k40-mir.....for-k40-laser/
You'll probably also want to adjust the tension on the drive belts. This is kind of a pain in the ass and I don't have a nice guide on it. You want them tight or they'll skip, but not too tight or they won't be able to run well.
Here's an awesome beginner's guide that basically goes over what I posted above plus more: https://www.reddit.com/r/lasercutting/wiki/k40
Since you are Trying to make boxes, I suggest looking into something called finger joints, this is probably the easiest way to assemble acrylic boxes.
One more warning, the k40, while cheap, is very much a DIY project. Working with it can be difficult if you have little experience modding machinary and playing with CNC programs. Also I suggest picking up a pair of CO2 laser goggles to protect your eyes while cutting/tuning the machine.
Some units have a Z axis table to help accommodate this with a powered lift. Some do automatic focus like mine, but it's a different class there. There are aftermarket Z axis powered tables for the K40. Laserbits.com used to be my go to location for mirrors, motor drivers, stepper drivers, etc, but they are gone now. Searching online for K40 parts will get you to a supplier.
One nice thing about the laser though is it makes it possible to not just make your own boxes, but also etch designs into them :3 so you can take a flat sheet, etch a pattern in, then have it cut the holes out, then cut the sides out so you can just stick them together to make a box yourself.
Also I forgot an important safety tip: don't ever run the actual laser with the work door open. By default they don't include any safety measures to keep that from happening. It's super tempting to hit that "test" button when aligning the mirrors without closing the door, but it's not worth the potential burn spots on the walls or on you.
When you plan on cutting transparent material, be advised that you'll need a infrared ( CO² )or UV laser.
The latter are dangerous and very expensive.
Not that IR lasers of the needed wattage ( 10W at the bare minimum, and then you're going to slowly grind your path through the material with multiple passes ) are cheap either.
Also, remember that laser systems tend to wear out.
Depending on usage you may have to plan a replacement laser diode every 6 months ( continued usage ) to 2 years ( 4h/day ).
Then again, last time I worked with such is over 15 years past.
They ARE hobby lasers. They may say CO2 40 watts, but that means it can do 40 watts at a very low duty cycle. This means you may have to make multiple passes to get through your material. This is not unusual with smaller units. You go higher in wattage or duty cycle (there's a difference) and you pay a LOT more.
Cast acrylic is what you want if you're engraving. Extruded stuff is more difficult to engrave or cut and tends to be more brittle. Also with Covid, you're going to have trouble finding any clear acrylic right now due to the need for this same material for breath shields at stores.
Colored acrylic, is about $10 for a 12x12 in square. You're going to waste a bunch learning. Just a fact you have to accept. TAP plastics is my choice there. They often have a scrap bin where you can buy leftovers for $2/pound which is great for testing with.
I finally gave in and went commercial. 40 watt Universal Laser Systems unit. Cost as much as my car at $14K, but geez, the difference is night and day. Full 100% duty cycle means single pass cuts, highly focused beyond what the K40 can do, lots of OEM support, and a larger 12x24 cutting bed. Oh, and powered Z axis (up and down). It's a commercial production unit, requires powered ventilation outdoors, etc. But I'm doing wood model structure kits for model railroading as well as furry stuff, so my needs are more commercial.
Glowforge is a good compromise between those two. They are also not cheap, but have good support, and can do quite a bit on the hobby side.
In short, if you want to tinker with hardware, settings, and hobby fun, learn with a K40.
If you want fire and forget at hobby level, Glowforge is ideal.
If you want to go all in, then it's commercial with Universal Laser Systems, Epilog, etc.
Youtube is very good for going over different models and what you can do with them. You're trading time and effort for results, so don't forget to factor in your time in your financial equations.
I’m a CNC guy, didn’t like the laser cutter.