100w 1200x900 Laser Build

[Tim Mellor]

After having Aluminium sources brought to my mind this morning thought I should check what I have and what my now more or less final layout is finished will need. I initially took a guesstimate based on Rob's plans and quantities and added a very non scientific fudge factor pre design.

Looks like I will need to add a few more metres of each flavour or in the case of the 2020 I could use up the V-slot I have. I can buy these online and keep below the usual 1000mm limit most evilbay or aliexpress sellers have for the rest.

Cut list is generated by Fusion 360 for those into CAD and it sure beats having to manually type a list

And Graphically via Mapboards/Fusion seems I still run out by a bit. Laid out the bits at 2000mm wide to look at all the bits using all the 1500mm V slot I have

[Gene Uselman]

I decided against a beam combiner (Hi Gene ) and I will be having a play with some Laser lines to form a cross on the head.

I went thru 4-5 iterations of the two laser lines before I gave in to reality and went with a combiner [and have appreciated it ever since ]. I would advise making room for it 'just in case'. The power loss on a large wattage tube is nonconsequential, if you start with 40w, it will have an effect. Gene out.

[Tim Mellor]

Without having to push the tube into an extension I can easily gain 30mm at the back still with clearance and Mirror 1 and 2 can come forward another 30mm without fouling anything so space should be fine if needed.

I have ordered 6 of those little Lasers so I planned to have a play on my little one first as the red dot on it is not even close to useful and I haven't used it since new.

Still mulling over ideas for the front air inlets but this idea or a variation on it is the current favourite. At 20 degrees open as shown it gives the equivalent of a bit over 5" duct diameter (I know that is a mixed up number but ) It also allows them to be shut down or reduced in airflow if using the Laser in pass through mode with the side doors open to play around with improving the extraction.

The three front sliding door arrangement is as per the original but I might do something a bit different yet. As is it should allow easy access under the bed as needed and maybe even a custom rake to design to get to the back.

[Gene Uselman]

I would make the front panels removable so that you can make changes as needed- experience will be more valuable than science in this case, I think. These posts are a good thing for us shut-ins. Thank you Sir.

I just watched the latest two of Russ' videos yesterday, it has me thinking about lightening the load on my laser head- my gantry is massive but the head's mass is what is more important for engraving.

[Tim Mellor]

The weight of the head was going to be reduced from stock with some Swiss cheesing but Russ's new folded lens holder looks interesting. The 3D printed option on this build also has some merit but not so much at 100W with the larger Nozzles viewtopic.php?f=159&t=4735

Still shut in here too albeit it with less risk but not being able to travel is a PITA so freight is choked up badly. The local postal service has described Parcel Levels above Christmas. It took 12 days recently for a Roll of 1 1/2" Vacuum hose to travel 300km Parcels from mainland China have been faster.

3D printers running for the morning, another Coffee first then time to make some Sawdust in the sunshine

[Tim Mellor]

More bits trickling in with the slowest part of being our local Post not the International part of it. Stepper drivers for the job and being Electronically minded I did the responsible thing and sliced the Warranty Void sticker and took it apart

Conformal coating is nice to have but the execution is a bit average (keeps the moisture off the board and components) The rest of it looks well laid out and well assembled and the two banks of four FETS are bolted to the 3mm thick case as a heatsink. https://www.aliexpress.com/item/4000785 ... 4c4dzXNnUp

Also another bunch of assorted Fasteners. The MGN15 Rail is in the country so I should get that early next week I hope.

[Tim Mellor]

Today's video from Russ clinched it for the optical bits to be used https://www.youtube.com/watch?v=W55YVMokjEM . I spent several hours re watching a bunch of his videos on Lens/Tube and Mirror combo's.

The Result was a series of Cloudray 'C' series parts but with weight reduction being the focus. I blame my R/C performance background as weight sucks when it comes to the top end performance, we used to shave a gram or two anywhere possible and the overall result was well worth it.

In the case of the new Lens Tube mounts the weight saving is HUGE over the stock C version so on larger engraves the speed and acceleration improvements are well worth the few $ extra plus the gain of vertical adjustment.

Ordered the adjustable frame from Cloudray as it hasn't hit AliExpress yet https://www.cloudraylaser.com/collectio ... ad-bracket

The Lens tube holder direct from Russ viewtopic.php?f=97&t=4765

Two Lens tubes 50/100 and 63/100
Three Lenses 50, 63 and 100
Three 25mm Mirrors
Combo Engraving Lens assembly with the 63 and 38mm Lenses per Russ. https://www.aliexpress.com/item/3295968 ... 4c4db71LE0
Belt Adjustment bracket to salvage the belt adjustment bits from https://www.aliexpress.com/item/3288520 ... 4c4db71LE0
Two Mirror #2's as it suits the Design better instead of the Pole mount #1.

Think apart from the Tube that is all of it


NOPE By not getting a complete C Head I forgot a Standard Nozzle FIXED

[Tim Mellor]

So today the MGN15 Rail finally turned up. UPS you SUCK! Freight is a 'bit backlogged' in Oz at present but it took UPS Three Weeks+ for the Australian part of the delivery and two inquiries from me, seriously WTF. No it wasn't held or opened by customs this is all on them.

On to the good stuff. The Rail came shipped in a solid tube in a plastic sleeve wrapped in bubblewrap then packed in an outer carton so well done to the seller I linked a few posts back - Recommended . The Bearing came with a nice simple plastic keeper to make sure all the balls stayed where they should and it made fitting onto the rail a breeze.

Both came with a really good coating of light machine oil but with a simple wipe at this stage movement was smooth and easy along the entire rail. The bearing slid at about a 30 degree angle and I will give it a proper solvent wash prior to fitting but it is back in the bag and resealed until then.

If you are playing with these on your own gear make very sure you don't have your balls drop so fit something at the end of the rail to stop the bearing coming off 'accidentally'.

Ordered the 6445G controller after taking a glance at alternates but it seems like the best spend for features at present. Just the Tube and HV Supply to go apart from some local bits and pieces. Leaning toward the Z100 Power Supply from Cloudray at present for the W2 Tube.

[Tim Mellor]

So I actually looked at what my Laser build is going to cost after buying nearly all the bits $4400 AU Pesos or just on $2800USD. Then there is a Cooler I am making from repurposed commercial fridge gear, Extractor (brought secondhand for $200) and an Airpump (already have a compressor)

So if anyone wants to build a big toy allow $3,500 USD or buy one already built for about $1000 more without the work but at least I won't have cut any corners

[Martin Overberg]

Tim, I am following your build with interest.

You might consider mechanically separating the laser mechanics and the trolley. The support frame with the four wheels will adapt to the unevenness of the floor and twist in the process. This could be avoided if it only had three wheels, but then it would tip over quickly.
I am considering using an open front trolley with four wheels. On this I would like to put a stiff, heavy frame on three supports, which serves as the basis for the mechanics. This gives an ergonomic working height (approx. 1.1 to 1.3 m) and space in the trolley for a unit for filtering the air and other auxiliary units:

base_on_trolley.png

stiff_base_for_mechanics.PNG