Laser Cutter Modification Project
To round out our design and fabrication curriculum we need to add one more component to the mix: engraving or cutting projects on a laser cutter. Although our students are already becoming familiar with the Inkscape design software, we still lack the laser cutter to fabricate their designs in something other than vinyl. Our Maker class is operating on a very tight budget, and the least expensive decent-quality laser cutters still cost thousands of dollars. Our current budget can't accommodate this. However, after doing extensive research online, it looks like it is possible to come up with a good quality laser cutter for a middle school or elementary setting for about $1200. This is significantly less than the cost of most entry-level laser cutters that I have seen available. How is this possible? Modify and upgrade a low-quality laser cutter, manufactured in China and available on eBay for about $500. This cutter won't have as large a work area and won't be as fast as more expensive models, but will be adequate for student projects at our middle school.
Online research revealed that, if you are comfortable with basic electronics and working with basic hand tools, your Maker skills can get this modified, lower-cost laser cutter up and running well. Many others have successfully made the modifications and have posted some of their work online. Unfortunately I haven't found a single web-posting that completely guides you through the steps to modify one of these units. I hope to remedy that by blogging my progress as we undertake modifying one of these cutters for safe and successful use at our school. Due to time constraints, (I do have my regular math and science teaching responsibilities to attend to first), the modifications most likely won't be finished until the start of the next school year in August. Much of the work will be done during the summer. I will invite interested Maker students to help in the modification process, assuming they want to help out during their summer vacation.
The basic laser and mechanical components of this low-cost cutter are solidly built and function well. However, the general consensus about this cutter is that the controller software and its related control electronics are TERRIBLE. There are also a number of safety and other enhancements that should be made to optimize the cutter's performance for a school setting.
The solution: replace the control electronics and software with something more standard and easier to use. There are a number of packages readily available for purchase that will do just that. We just need to remove the old components and install the replacements. We will also need to install a safety interlock switch that turns the laser off if the lid is opened while the unit is operating. The X and Y axis end-stop optical sensors should be replaced with mechanical switches, the ventilation fan housing and hose should be upgraded, and an air-assist nozzle and pump should be added. Other enhancements include laser-pointer alignment mounts on the cutter head (you can 3-D print this!), as well as an adjustable motorized cutting bed. This sounds like a lot of work, but most of the parts for these modifications are easily available and are relatively inexpensive.
Making all of these modifications will require significant disassembly of the original low-cost laser cutter. Instructions to guide you through the upgrades already exist but are scattered across the Internet. I have created bookmarks to these sites to assist in our modification project. I expect the work will be interesting, fun, and likely frustrating at times. However, if we are successful, we will not only have made laser cutting and engraving an affordable addition to our Maker curriculum, we will know the mechanics of our cutter inside and out. This will make future modifications and repairs much simpler, not to mention the added satisfaction we will have gained from having "rebuilt" the cutter ourselves.
I have already purchased the low-quality cutter on eBay for $489, including free shipping. The unit arrived intact. It is now sitting on the work-shelf in my classroom, awaiting the first steps of disassembly. We hope to begin that process in the next month or so. As the project progresses I will post updates along with links to related resources and materials suppliers, so others can use this as guide should they wish to attempt this project. My next post about this project should appear by mid-June.
