100w 1200x900 Laser Build

[Tim Mellor]

While I have already accumulated and ordered a heap of bits for this build already today I got stuck into the design mods and redrawing the CAD files from the original.

viewtopic.php?f=159&t=4147

List of mods so far.

Bed is now 930 wide and the Gantry travel is 1250 so I am calling this a 900x1200 bed with a bit to spare.
Modified the Frame design to allow for end to end pass through of material so 900 wide x whatever.
Tweaked the original 80W Laser drawing to reflect the bigger W2 Reci I am planning to use.

First installment and hopefully with a construction start time of early June depending on how the freight goes.

For simplicity of the Cad work and to make it cleaner to look at I won't be modelling the V slot profiles or adding a lot of the detail that Rob has included in his model this is a working drawing for me to test fit and provide a cut list of aluminium.

[Tim Mellor]

Spent some time starting to sort out the enclosure size today. Allowance for the 2020 frame has been made to clear all the parts. My plan is to fit both power supplies, stepper drivers and the main relays and power/safety switch into this frame but the Ruida controller and other instruments to be plugged into it for external mounting to save space.

The Stepper Drivers will sit in under any likely pass through needs. Additional main power and isolation switches not shown fill fit into the front corner under the Tube. At this stage I will be mounting a PC/Monitor and the controller on an Arm but this is still up for final design and thought process.

Current size is 1650x1400x440 (LxWxH) plus the base shown at 625 for a height of 1065mm.

edit added an end of the day render with a base shown. Most likely done in black skinned formply rather than exposed ply.

[Gene Uselman]

Very nice- have you been thinking about a bed [like a blade bed]?

[Tim Mellor]

With the bed I am going to consider it as a flexible one and try some different things viewtopic.php?f=125&t=4714 I will see about getting a price on the blades in the next few days and add it to that that thread.

The 1/2 honeycomb will be a 'nice to have' but not essential and a Pin bed for aligning jigs or repeat jobs on makes sense to my Engineering brain.

After midnight and I have scribbled my last note in the book so I will try and switch off the brain for a few hours

[Gene Uselman]

I read your older post after I saw this one. The honeycomb with points will be similar to a pin bed and it is suboptimal in my humble opinion. I use my blade bed 95% of the time, I do get flashback but usually I am interested in one side and if I need two sides the piece can be elevated enough to work nicely. Nothing is perfect, the blades do get gunked up but I soak them in lacquer thinner every couple years. I actually priced the alum blades a few years back but the price was quite high as I recall. If I were to make them I would use 1/8" steel with 1/32" a bit taller riveted or tack welded on one side. My practice it to space them every 1.75" on the half I use most and 3.5" on the other side [which I keep covered]. Make a handy place to put all your offcuts that you intend to use quickly- just keep the pile below the level of the gantry [and especially the laser beam], ask me how I know

[Tim Mellor]

I will keep the Bed design in the other thread at this stage. Added a custom spacer block just for you @Gene

End of the day Render. Most of the external framing is in place, just some tweakage to do.

I have shown it with cladding removed so the insides can be seen. There will be some internal panels to protect the tube from a stray knock but those covers will be supported from the outer shell not the working frame. The same thing will apply for keeping the smoke and fumes away from the Electronics as much as possible and they should have their own fan system. The theory is even if you bump the outer frame heavily the working frame/gantry/Tube is completely independent other than sharing a base board.

[Tim Mellor]

The last of the Aluminium arrived today along with the Steppers for the build. Hoping our little Aussie $ peso recovers some more lost ground before I order the big $ items.

[Tim Mellor]

Ordered another bunch of bits today including the Stepper Drivers and the last of the transmission bits. Also did a little local shopping for construction supplies One is a low rake Aluminium/Acrylic blade for my Tracksaw to use on the V and T slot and the other is just a prop

[Tim Mellor]

Still working on the design but an end of day render with the likely Signboard cladding shown. https://www.sassignage.com.au/aluminium ... panel.html This finish will depend a little on budget but when combined with the edge trim will make it look less homebrew than simple sheetmetal screwed to the 2020. Localized plain Steel panels on the parts where direct Laser is possible including the floor to limit reflected power.

Sort of visible is the Left side pass through door. It will just drop down if needed with a matching one on the right side. Still working on the air inlet options for the front part of the door but there won't be any dodgy blocks of wood holding it open

The trolley is overkill (torsion box top and shelf) but I have a preference for getting it right from the ground up Flat, Square and Straight will make the rest of the build easier and less prone to being a PITA when moved over it's life for alignment.

[Gene Uselman]

ACM [alum clad plastic core material] is an excellent choice, strong and light. We buy 3mm sheets 25 or 50 at a time [$35-40 a sheet] and it has replaced 1/2" MDO plywood and .040-.080 aluminum, thankfully. It is also available [not as commonly] in 1 and 2mm BTW. I can't see what you are thinking of for a baffle between the cutting area and the tube, but this should be sealed as well as possible and I would use a positive pressure cooling for that area. Best, Gene