Laser Cutter: Difference between revisions

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=Machine Information=
[[Category:Tools]]
* Owner: Backyard Brains
[[Category:Requires Maintenance]]
* Who Can Use: Roger S., Josh W., and Zach S, Alex C., Vanya P., Nick R. currently have experience running this LASER. Greg G., and Tim M. purchased it. Accordingly, they can do whatever they want with it ; )


=Status: Temporarily Operational=
=== Intro ===
* The machine is up and running, but we lack:
The cutter has an 80W infrared CO2 DC laser, with a 1400mm x 900mm bed. It essentially burns away small portions of material to make its cuts. Designs are created in or imported into [https://lightburnsoftware.com/ LightBurn], which is responsible for tweaking and downloading the design to the laser cutter. Lightburn is installed on the control computer, and is available at a discount to AHA members. The discount code is posted on the laser cutter. The laser is a Jinan TransonCNC [http://www.transoncnc.com/product/showproduct.php?id=136&lang=en 1490A] in a [http://www.transoncnc.com/product/showproduct.php?id=117&lang=en 1490B] shell, for easier disassembly when it needs to be moved around. It is well suited to precise and repeatable cuts on flat and relatively thin material, such as for art or particular parts. Materials such as paper, certain woods, or acrylic work well, but some simply won't cut, or are dangerous to cut, such as chlorine-containing plastics.
** Permanent filtering/ventilation
** Documentation
** Price info


Josh Williams is currently the primary contact for the installation process.
== Safety ==
There are 3 main safety issues when using the laser cutter. These are covered in the class that is required to use the laser, but are also covered here.


=General usage information=
=== Fire ===
This is very temporary and very much in flux. If you have not been given permission to use the laser cutter by Greg Gage, Tim Marzullo, or Josh Williams, please don't use the cutter. Training opportunities will be available soon!
Because the laser essentially burns material to make its cuts, there is always a risk of fire. Because of this, you must supervise your cuts the entire time, and be prepared to stop the cut if a fire is started. Different materials are at different levels of risk of fire. Very thin materials have the highest risk for fire, although nothing is 100% safe.


i3 Detroit has a similar laser cutter and a very nice wiki: http://i3detroit.org/wi/index.php?title=Laser_Cutter_-_Bumblebee
In case of fire:
# Hit the Emergency Stop Button.
# Open the hood and remove the work piece from the machine if possible.
# Use your best judgement to put out the fire. Many can be smothered or blown out. Use the loud noise room fire extinguisher to put out the fire if necessary.


Their power/speed settings won't correspond with ours, as their cutter is 150 watt, this one is 80.
=== Cutting Unsafe Materials ===
For unsafe materials, simply put, it is dangerous to cut certain materials with the laser cutter. Please consult one of many materials lists, such as the [https://www.i3detroit.org/wiki/Laser_Materials_List i3 Detroit] or [http://atxhackerspace.org/wiki/Laser_Cutter_Materials ATX Hackerspace] lists. This is easy to manage by knowing what your material is made of, and only using safe materials.


Commonly cut materials that behave well are sheets of acrylic (make sure it's meant for laser cutting), and thin woods. Some woods that are hard or oily may be more trouble than they're worth to cut, or may produce excessive amounts of smoke. Other materials like foil-backed paperboard may cut fine from the paper side, and hardly at all from the foil side. Unsafe materials like PVC, and other plastics containing chlorine, are unsafe to cut, as they will produce [https://en.wikipedia.org/wiki/Chlorine#Hazards Chlorine gas] when cut. If you accidently cut chlorine containing plastics, it will produce a yellow, acrid gas. Stop the machine and evacuate the room. The volume of chlorine gas produced per second will be low, but could be dangerous to individuals with breathing difficulties. Chronic exposure is also dangerous.


=== Damaging the Machine ===
Using the laser cutter involves moving the cutting head around, but hitting the head against the work piece or ramming it into the bed surface can break the cutting head and require expensive repair. Avoiding this just requires paying attention while manually moving the head in the X and Y axes, and being very careful when adjusting the bed height (Z axis) to not ram the head into the work piece or cutter bed. This also means that only your work piece should be in laser when cutting, so that there isn't anything to run into.


==Turning everything on==
Also, the industrial chiller must be running to cool the laser tube. Without cooling the laser cutter should not be used, as the tube can be quickly damaged without cooling.
# Find out where the Big Red Emergency Stop button is on the laser cutter.
# Find out where the fire extinguisher is
# Turn on the Power strip next to the computer
## This should turn the chiller on which makes a beeping noise for 5-10 seconds.
## '''If you don't hear a beeping noise, something is wrong. Please stop here.'''
# Turn on the computer
# Turn on the LASER Cutter using the laser key.  
## Key is located in the laser cutter toolbox above the laser computer.
### The bed of the laser should light up, if not there is an on off switch on the side of the laser below the control panel.
# Turn on the Filter (temporarily located in the boiler room behind the laser cutter)
# Turn on the Blower (temporarily located in the boiler room behind the laser cutter)


==File prep & loading your material==
Cutting some materials can also increase the need for maintenance on the machine. Chlorine gas from vinyl is hazardous to health, but also corrodes the machine. Cutting polycarbonate is not hazardous to health, but  does create lots of smoke which settles on the laser tube, mirrors, and on the linear rails.  
# On the computer, launch "LASERCut 5.3" from the desktop
# Place the material you are cutting towards the center of the laser bed
## If the bed is too high, use the "Z-" within the lasercut software to lower the bed.
# Use the x and y panel within the Lasercut software to position the laser head at the top left corner of your object
# Use the "Z Datum" button on the computer to set the laser at the right height.
## The laser must be positioned on top of your material for this to work accurately
# Adjust your speed & power settings in the top right hand corner in accordance to your needs.
## This has not been covered yet.
##3mm Orange Acrylic: 100% power @ 15% speed seems to cut through in one pass.
## Setting the power around 10% does not seem to enough to fire the laser. Choose something higher.
# Set the laser origin to "top left" by:
## Select everything (Ctrl-A)
## Tools Menu -> Set laser origin
## Check "Relative to Selection" and choose "Left-top"
# Select the "Pick" mouse cursor tool
## Make sure your design is still selected
## Hit the Space Bar
## Select "Left-top"
# Unite lines
## Select all of your design
## Click the "Tools" menu
## Choose "Unite lines"
### This should make your life easier. When you import an item into lasercut it generally breaks up all of your lines into individual lines to cut, stopping and starting the job instead of running a continuous line. However, it might do funny things. It's best to '''zoom in to your design''' to get a better idea of what's happening. The zoomed out view does not show as much detail.


==Test==
== Instructions ==
# When you have everything setup, click "Download"
You must be trained on this LASER before using it. Get trained by [http://www.allhandsactive.com/events/ taking the class]! The class covers all this info, but it is covered here as well.
## Select "Download Current" to load your design on to the laser cutter
## Select "Run Box" to do a perimeter test.  


==Burn==
* [https://docs.google.com/presentation/d/1SrZXzwGMaWvcrB7dGKYKKsITLRnAqrLa9Spj8IChhcc/edit?usp=sharing Detailed Checklist] for Big Red
# Double check to make sure the filter, blower, and chiller are on.
* Simplified Checklist for Big Red: http://goo.gl/jM9vem
# Click "Start" to begin your burn.
# '''Do not leave the laser cutter while your burn is going'''


==Shutting down and cleanup==
=== Turning On ===
# Turn off the laser cutter computer
All necessary components are wired into the surge protector on the back right part of the machine, so turning them on is just a matter of hitting the red switch on the surge protector. This turns on the fan for the exhaust, the industrial chiller, and the laser cutter itself. The computer itself is on a different outlet, and normally just stays on.
# Turn off the power strip that the laser cutter & chiller are connected to
# Turn off the power strip for the blower
# Turn off the power strip for the filter
# Check the bed below the laser cutter. If you were cutting out small pieces they will fall below the honeycomb bed.


==Interesting Issues==
When turning the machine on, make sure that the industrial chiller beeps, and that the fan spins up. The chiller will also have a readout on the front of the current water temperature in Celsius.
# When running an outline of a Moai head, the laser stopped and started at various points for a very brief moment.
## We simplified the outline in inkscape and made sure to unite lines in lasercut 5.3. This helped, but we still stop/start problems with the laser.
# It appears that if your image/vector file is greater than any dimension of the bed (140cm * 90cm), the software will crash upon opening.
=== Occasional divets noticed when cutting through acrylic===
Material: 3mm Clear Acrylic
* Divet pattern may correspond to honeycomb outline?
* Mentions reflection issue from honeycomb: http://www.sawmillcreek.org/showthread.php?199099-Knife-table-verses-honeycomb-table


=Steps to get it running=
=== Turning Off ===
* <del>Reconnect electronics (disconnected during leg removal)</del>
Everything is safe to turn off by turning off the surge protector, just like turning the machine on. This turns off the cutter, the fan, and the chiller. The computer is generally left on.
* <del>Go over LASER cutter, compare with manual.</del>
* <del>Install Tube</del>
* <del>Connect power to LASER Cutter: Boots</del>
* <del>Connect Air Compressor to LASER: Working</del>
* <del>Connect power to Chiller, connect alarm cable to laser: Works</del>
* <del>Test Jogging X/Y/Z</del>
* <del>Super brief test firing: Works</del>
* <del>Align Mirrors</del>
* <del>Figure out placement of computer/monitor</del>
* <del>Install lasercut software & test connection to laser</del>
* <del>Remove Metal Cutting Board (below honeycomb)</del>
* <del>Fix hood closing issue (catches on right side)</del>
* <del>Install hood handles</del>
* <del>Organize Air & Water Tubing</del>
* <del>Mount Air Compressor to floor</del>
* <del>Where is hole for ventilation?</del>
* Where to exhaust to?
* How much to exhaust out of building (top)
* Filter: We are testing the RSU 20CCHR Electrocorp


=Notes specific to the install at AHA=
== Design ==
* Water Chiller installed underneath laser. Pull laser forward ~4' in order to access. ''' Be careful to avoid crushing or pulling out tubes for air & water'''
The laser cutter can only use vector files for cutting or engraving. Many .svg files are available on the web at sites like https://freesvg.org/ and https://thenounproject.com/ are good options for finding files if you aren't an artist yourself. These files can be opened directly with Lightburn.
* Air Compressor installed underneath laser. Pull laser forward ~4' in order to access. ''' Be careful to avoid crushing or pulling out tubes for air & water'''
* Currently two power strips are utilized, each connected to a separate circuit
** The laser itself connects to the red spray painted outlet. '''This circuit is accessible from two other places within AHA. This should be avoided!'''
** The Computer and Water chiller connect to the outlet adjacent to the red spray painted outlet. The blower will also likely be connected to this outlet


=What was Ordered=
Jinan TransonCNC [http://www.transoncnc.com/product/showproduct.php?id=136&lang=en 1490A] in a [http://www.transoncnc.com/product/showproduct.php?id=117&lang=en 1490B] shell. (It comes apart easier for the purpose of fitting through our front door)
* We have been told that everything is outfitted to run on standard 120ac (LASER Cutter, Chiller/Pump, and Exhaust)
* LASER Power Reci80W
* Weight: ~450 kg (1000 lbs)
* Equipment Dimension Top Half 192*131*42cm
* Equipment Dimension Bot Half 192*131*70cm
* Working Area 140cm*90cm
* Metal Slat Table
* Motorized up and down table
* honeycomb table
* Red Dot pointer
* Auto Focus
* Extra Reci80W (LASER Tube)
* Extra Lens & Mirror
* Extra Motion Card (Controller)
* Extra Belt - X Axis
* Extra Belt - Y Axis
* Extra Motorized up and Table Belt
* Extra Girdle Belt
* Extra X Motor
* Extra Y Motor
* Extra Z Motors (2)
* LASER Goggles
* CW3000 Water Chiller


It is sometimes useful to have single stroke fonts which can be used with a low power cut instead of the engrave function. Text can be generated using https://www.templatemaker.nl/singlelinetext/ or https://martenjacobs.github.io/LineFont/linefont.html


=Exhaust=
When making assemblies, you may want to use this script to add joinery to the edges: https://www.instructables.com/Joinery-Joints-for-Laser-Cut-Assemblies/
* Exhaust Port: 6"
* CFM ~512


== Maintenance ==
Maintenance should only be done by experienced and qualified laser lords, or with their supervision. Much routine maintenance is easy and safe to do, but the machine is quite sensitive, and repairs are potentially expensive. If you think that the laser needs maintenance, join our matrix server at [https://chat.allhandsactive.org/#/welcome chat.allhandsactive.org] and contact the Laser Cutter channel. You may also email [mailto:Board@allhandsactive.org board@allhandsactive.org].


=Manuals=
Generally the machine periodically needs:
* Software Manual: https://drive.google.com/file/d/0B9x4RIcqwUojamYxMkswT3EwUWtFVWpwMHpZM0ZRN2hyRFdr/edit?usp=sharing
* rails & bearings cleaned and lubricated
* mirrors cleaned
* lens cleaned
* laser tube replaced (as necessary; wear item)
* lower chamber cleaned of cut remnants
* belts and other tidbits replaced as necessary
 
== History ==
The laser was originally owned by Backyard Brains, and has been donated to AHA when they moved out. Thanks! It was also part of a group order, where i3 Detroit received 2 nearly identical lasers, so their own documentation is very helpful. See their [https://www.i3detroit.org/wiki/Laser_Cutter_-_Bumblebee Bumblebee laser cutter] wiki page. The controller was upgraded in 2023 to a [https://www.ruidacontroller.com/rdc6442s/ Ruida RDC6442S]. This controller is compatible with two different control softwares,[https://lightburnsoftware.com/ LightBurn], and RDWorks V8. Lightburn is the preferred software and is installed on the control computer. In addition, lightburn is available at a discount to AHA members. The discount code is posted on the laser cutter.
 
== References ==
* Software Manual: https://drive.google.com/file/d/0B9x4RIcqwUojamYxMkswT3EwUWtFVWpwMHpZM0ZRN2hyRFdr/edit?usp=sharing (depreciated)
* Ruida Controller Manual: https://drive.google.com/file/d/1xWPSj5Fq1dYQxb54TRhUhFM0FNFmWPCF/view?usp=share_link
* Machine Manual: https://drive.google.com/file/d/0B9x4RIcqwUojbm5tdzI2ZnFmV291anZBS0RaZGlOVXQweUZz/edit?usp=sharing
* Machine Manual: https://drive.google.com/file/d/0B9x4RIcqwUojbm5tdzI2ZnFmV291anZBS0RaZGlOVXQweUZz/edit?usp=sharing
* Chiller Manual: https://drive.google.com/file/d/1h4K1ct3wl8PC46AfI-M--XA0x2hsqCWX/view?usp=share_link
* General info from Rabbit Laser: https://rabbitlaserusa.com/ManualsTutorials.html


= FAQ =


=Ongoing Maintenance Costs=
Put common questions and their answers here!
==Regularly Recurring==
* Filters
* Activated Charcoal?
* de-ionized water
* LASER Tubes
==Occasional==
* Replacement Hardware on LASER (Motors, Belts, etc.)
 
=Ongoing Maintenance=
* Who is responsible for the work?
* Who is responsible for the costs?


=Training=
The [https://www.i3detroit.org/wiki/Laser_Cutter_-_Bumblebee#FAQ i3 Detroit Laser FAQ] is a good start/reference.
* TBD once we have the machine. See the manuals linked above for "What we know now"

Revision as of 23:58, 21 January 2023


Intro

The cutter has an 80W infrared CO2 DC laser, with a 1400mm x 900mm bed. It essentially burns away small portions of material to make its cuts. Designs are created in or imported into LightBurn, which is responsible for tweaking and downloading the design to the laser cutter. Lightburn is installed on the control computer, and is available at a discount to AHA members. The discount code is posted on the laser cutter. The laser is a Jinan TransonCNC 1490A in a 1490B shell, for easier disassembly when it needs to be moved around. It is well suited to precise and repeatable cuts on flat and relatively thin material, such as for art or particular parts. Materials such as paper, certain woods, or acrylic work well, but some simply won't cut, or are dangerous to cut, such as chlorine-containing plastics.

Safety

There are 3 main safety issues when using the laser cutter. These are covered in the class that is required to use the laser, but are also covered here.

Fire

Because the laser essentially burns material to make its cuts, there is always a risk of fire. Because of this, you must supervise your cuts the entire time, and be prepared to stop the cut if a fire is started. Different materials are at different levels of risk of fire. Very thin materials have the highest risk for fire, although nothing is 100% safe.

In case of fire:

  1. Hit the Emergency Stop Button.
  2. Open the hood and remove the work piece from the machine if possible.
  3. Use your best judgement to put out the fire. Many can be smothered or blown out. Use the loud noise room fire extinguisher to put out the fire if necessary.

Cutting Unsafe Materials

For unsafe materials, simply put, it is dangerous to cut certain materials with the laser cutter. Please consult one of many materials lists, such as the i3 Detroit or ATX Hackerspace lists. This is easy to manage by knowing what your material is made of, and only using safe materials.

Commonly cut materials that behave well are sheets of acrylic (make sure it's meant for laser cutting), and thin woods. Some woods that are hard or oily may be more trouble than they're worth to cut, or may produce excessive amounts of smoke. Other materials like foil-backed paperboard may cut fine from the paper side, and hardly at all from the foil side. Unsafe materials like PVC, and other plastics containing chlorine, are unsafe to cut, as they will produce Chlorine gas when cut. If you accidently cut chlorine containing plastics, it will produce a yellow, acrid gas. Stop the machine and evacuate the room. The volume of chlorine gas produced per second will be low, but could be dangerous to individuals with breathing difficulties. Chronic exposure is also dangerous.

Damaging the Machine

Using the laser cutter involves moving the cutting head around, but hitting the head against the work piece or ramming it into the bed surface can break the cutting head and require expensive repair. Avoiding this just requires paying attention while manually moving the head in the X and Y axes, and being very careful when adjusting the bed height (Z axis) to not ram the head into the work piece or cutter bed. This also means that only your work piece should be in laser when cutting, so that there isn't anything to run into.

Also, the industrial chiller must be running to cool the laser tube. Without cooling the laser cutter should not be used, as the tube can be quickly damaged without cooling.

Cutting some materials can also increase the need for maintenance on the machine. Chlorine gas from vinyl is hazardous to health, but also corrodes the machine. Cutting polycarbonate is not hazardous to health, but does create lots of smoke which settles on the laser tube, mirrors, and on the linear rails.

Instructions

You must be trained on this LASER before using it. Get trained by taking the class! The class covers all this info, but it is covered here as well.

Turning On

All necessary components are wired into the surge protector on the back right part of the machine, so turning them on is just a matter of hitting the red switch on the surge protector. This turns on the fan for the exhaust, the industrial chiller, and the laser cutter itself. The computer itself is on a different outlet, and normally just stays on.

When turning the machine on, make sure that the industrial chiller beeps, and that the fan spins up. The chiller will also have a readout on the front of the current water temperature in Celsius.

Turning Off

Everything is safe to turn off by turning off the surge protector, just like turning the machine on. This turns off the cutter, the fan, and the chiller. The computer is generally left on.

Design

The laser cutter can only use vector files for cutting or engraving. Many .svg files are available on the web at sites like https://freesvg.org/ and https://thenounproject.com/ are good options for finding files if you aren't an artist yourself. These files can be opened directly with Lightburn.


It is sometimes useful to have single stroke fonts which can be used with a low power cut instead of the engrave function. Text can be generated using https://www.templatemaker.nl/singlelinetext/ or https://martenjacobs.github.io/LineFont/linefont.html

When making assemblies, you may want to use this script to add joinery to the edges: https://www.instructables.com/Joinery-Joints-for-Laser-Cut-Assemblies/

Maintenance

Maintenance should only be done by experienced and qualified laser lords, or with their supervision. Much routine maintenance is easy and safe to do, but the machine is quite sensitive, and repairs are potentially expensive. If you think that the laser needs maintenance, join our matrix server at chat.allhandsactive.org and contact the Laser Cutter channel. You may also email board@allhandsactive.org.

Generally the machine periodically needs:

  • rails & bearings cleaned and lubricated
  • mirrors cleaned
  • lens cleaned
  • laser tube replaced (as necessary; wear item)
  • lower chamber cleaned of cut remnants
  • belts and other tidbits replaced as necessary

History

The laser was originally owned by Backyard Brains, and has been donated to AHA when they moved out. Thanks! It was also part of a group order, where i3 Detroit received 2 nearly identical lasers, so their own documentation is very helpful. See their Bumblebee laser cutter wiki page. The controller was upgraded in 2023 to a Ruida RDC6442S. This controller is compatible with two different control softwares,LightBurn, and RDWorks V8. Lightburn is the preferred software and is installed on the control computer. In addition, lightburn is available at a discount to AHA members. The discount code is posted on the laser cutter.

References

FAQ

Put common questions and their answers here!

The i3 Detroit Laser FAQ is a good start/reference.