Laser Cutter Alignment Mod Skips Beam Combiner

A lot of the DIY laser engravers and cutters we cover here on Hackaday are made with laser diodes salvaged from Blu-ray drives and projectors, which are visible lasers in the 400 – 450nm range (appearing as violet or blue). Unfortunately there is an upper limit in terms of power on visible diode lasers, most builds max out at 5W or so. If you need more power than that, you’ll likely find yourself looking at gas laser cutters like the K40. While the K40 is a great starting point if you’re looking to get into "real" lasers, it's a very different beast from the homebrew builds using visible lasers.

With a gas laser the beam itself is invisible, making it much more difficult to align or do test runs. One solution is to add a visible laser to the K40 which can be used to verify alignment, but making sure it's traveling down the same path as the primary laser usually requires an expensive beam combiner. Looking to avoid this cost, [gafu] wanted to see if it was possible to simply move the visible laser into the path of the primary beam mechanically.

In the setup that [gafu] has come up with, a cheap laser module (the type from a handheld laser pointer) is moved into the path of the primary laser on an arm that's actuated by a simple hobby servo. To prevent the primary and visible lasers from firing at the same time, an Arduino is used to control the servo given the current state of the K40's lid. If the lid of the K40 is open, the primary laser is shutoff and the visible laser is rotated into position so the operator can see where the primary laser's beam would be hitting. Once the lid is closed, the visible laser rotates out of the way and the primary is powered back up.

Running the cutting or engraving job with the lid of the K40 machine open now let's [gafu] watch a "dry run" of the entire operation with the visible laser before finally committing to blasting the target with the full power beam.

We’ve covered many hacks and modifications for everyone's favorite entry-level CO2 laser cutter. From replacing the controller to making it bigger, K40 owners certainly seem like a creative bunch.