60$ Laser Engraver - Cutter - Instructables

Home Sign Up!
Browse Community Submit

All Art Craft Food Games Green Home Kids Life Music Offbeat Outdoors Pets Photo Ride Science Tech
$60 Laser Engraver / Cutter

by cgosh on June 5, 2007
Table of Contents
$60 Laser Engraver / Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intro: $60 Laser Engraver / Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 1: First things first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2: Rough Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 3: Tools You'll Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 4: Materials You've Gotta Have . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 5: Make the Pantograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 6: Pick Your Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Step 7: Laser Stuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 8: Assemble the Laser Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 9: Ready to Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 10: Adjust the Laser Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 11: Put the Pieces Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 12: Burn Some Stuff ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
http://www.instructables.com/id/60-Laser-Engraver--Cutter/
Intro: $60 Laser Engraver / Cutter
I drool on my keyboard when I look at those fancy laser cutter/engravers that cost $$thousands, so I figured out how to make one for $60. That's right -- 60 bucks.
My design is not EXACTLY like the multi-$1,000 models, but it will let you do a lot of the same work. Figure on 'manual' rather than 'computer-operated'. This means you
don't have to learn CAD, or even have a computer. It can also be used as a portable (bonus!). Did I mention it only costs $60?
When I saw the cutting laser that Stephanie Maksylewich made, I knew all that was missing was some way to control where it points and burns, and a variable AC power
supply to control the intensity. See the video here .
I decided to mount a cutting laser on a pantograph , (and see below) used for centuries to copy, enlarge, and shrink an existing drawing. But instead of a pencil lead
making the duplicate, we'll use the laser to cut or engrave.
I built a variable power supply out of 10 simple electrical pieces, and a pantograph out of four yardsticks and some nuts and bolts.
Remember to always treat this device with respect -- it's an industrial-strength handheld power tool, even if it looks homebrewed.
Image Notes
1. High-powered, pinpoint, low-voltage LED laser goes here. It burns a smaller
size, equal size, or larger size copy of your original by tracing it with a stylus (seen
here on the right). If you want to make the burned/etched copy bigger than the
original, swap the laser with the stylus.
2. This spot stays steady on your work surface.
3. A stylus here traces your original drawing or text.
4. Power supply, controls, wiring not shown here, for clarity. This is not a difficult
instructable, requires no special tools, no advanced skills, etc. It does require you
to use safety and common sense when working with the laser. It burns stuff. Fast.
5. Yardsticks, nuts and bolts form this pantograph. This is an old-time gizmo for
copying drawings, can also change the size from the original.
6. Pantograph works by maintaining a constant ratio between two moving points
(laser and tracing stylus). Very easy to use. Been around for a few hundred years.
Step 1: First things first

First, read through this entire instructable before buying or assembling anything.
I'm using mine to prototype a new product, and I couldn't justify putting $$thousands$$ on my credit card to test my idea. Maybe you'll come up with a way to make some
cash. If you can afford 60 bucks and some time, you might be in the laser engraving and cutting business next week (it takes a few days for parts to arrive in the mail).
Important!! You must be over 18. This is NOT a toy. It'sa powerful industrial-strength tool. Adults only. Period. It burns holes through plastic fast. You should probably
have a fire extinguisher nearby, which you probably already own if you're up for this kind of mischief.
You can easily dial the power down and just etch the surface of your stuff. Get plenty of practice on materials you don't need <<before>> you etch your buddy's laptop.
There's a big learning curve on the $10,000 models, but at least they come with lots of instructions. These are my instructions . . .
I am not responsible for anything you (or your assigns) damage, burn or toast for any reason. Not responsible. Et cetera. Not responsible.
Maybe some kind readers will enlighten all of us with their experience and knowledge in Forum or Comments sections describing some tricks of the trade for using laser
cutter / engravers. (Other than, "Get a real one," please.) This does not include drawing toast pictures on bread.
There's nothing difficult, no special tools, and not a whole lot of skill involved. It's actually fiendishly simple. I've put in a lot of details, so this instructable looks longer than
it really is.
Use common sense, and safety first.
Let's engrave some stuff!
Step 2: Rough Description
You'll need a drill and drill bits if you make your own pantograph, some epoxy or silicone caulk, tape, rubber bands, ballpoint pen or pencil, toothpicks, needle nose pliers,
wire cutters and stripper, etc. Nothing fancy.
Build a DVD burner laser as Stephanie shows.
Either use a breadboard to assemble the power supply, or you'll solder a few wires and connections with a solder pencil. If you've got shaky hands, go with the
breadboard.
Order the electronic parts through the mail, get a few pieces from Radio Shack, and one item on eBay.com (seller has 99+% positive feedback).
Build the pantograph from yardsticks and nuts & bolts or buy one here and practice using it while you wait for the other stuff to arrive. Practice soldering a few wires
together to get the hang of it.
When the electronic parts arrive, solder them together and stick them on to the pantograph. Take a few minutes to learn how it all works and let the laser cutting and
engraving begin!
Basically, this is a solid-state, red, visible, LED laser beam shining through a small lens to focus the beam, just like focusing the sun through a magnifying glass. It has a
'focal point' -- a specific distance away from the lens where the beam is focused down to a tiny point.
It's mounted on a pantograph (see photos), one of those parallelogram-looking gizmos used to copy a drawing while making it larger or smaller. Instead of copying your
drawings in pencil lead, you'll use an LED laser.
A fingertip switch where you hold the pantograph at the stylus turns the laser on and off instantly so you can skip around. Variable power (burning/heating ability) for the
laser is controlled by a volume-control-like slider that runs a simple 3-wire voltage regulator, which is supplied by any power supply you can scavenge (or buy) that's rated
from 4 Volts to 32 Volts DC at 1 Amp or better.
If that was all gibberish to you, just stick with us and it will become clear.
Look on any power supply and you'll find the rating. If your power supply is smaller than 1 Amp (may be called 1,000 mA), that's OK, but the power of the laser beam will
be less. Many folks (especially folks who frequent this website) have SOME kind of old power supply / power brick / outlet brick laying around looking for a new home. If
you're really living thin, ask your friends and neighbors. Otherwise, you can get one for around $11 from MPJA.com .
My skinny $60 budget did not include the power supply, as I have lots of them around, so your cost might be $71. Before complaining too loudly, take the $5,929 you
saved and buy yourself a really nice milk shake to cool down. Then let's get back to work . . .
Image Notes Image Notes

1. High-powered, pinpoint, low-voltage LED laser goes here. It burns a smaller 1. Move the 'A' bolt and the 'B' bolt to the middle of their sticks and you get a 2-
size, equal size, or larger size copy of your original by tracing it with a stylus to-1 drawing ratio. Put the laser on the right and the tracing stylus on the center
(seen here on the right). If you want to make the burned/etched copy bigger knee, and you'll double the size of the original. Switch the laser and the stylus
than the original, swap the laser with the stylus. (that is, stylus on the left end and the laser in the middle knee) and you'll get a
2. This spot stays steady on your work surface. result that's one-half the size of the original drawing.
3. A stylus here traces your original drawing or text. 2. Stylus goes here to enlarge. Laser goes here to reduce.
4. Power supply, controls, wiring not shown here, for clarity. This is not a 3. Stylus goes here to reduce the size of the original drawing Laser goes here to
difficult instructable, requires no special tools, no advanced skills, etc. It does double the size of the original drawing.
require you to use safety and common sense when working with the laser. It 4. This is the 'B' bolt stuck in the middle of the yardsticks.
burns stuff. Fast. 5. This bolt always remains in these holes.
5. Yardsticks, nuts and bolts form this pantograph. This is an old-time gizmo for 6. This bolt is always in this hole and always mounted solidly to your work
copying drawings, can also change the size from the original. surface.
6. Pantograph works by maintaining a constant ratio between two moving points
(laser and tracing stylus). Very easy to use. Been around for a few hundred
years.
1. Laser goes here if you want to expand your original. Stylus traces your 1. Switch the laser (or marker) here and trace with the end of the right leg to
original here if you want to reduce it. dramatically reduce your original. This spot doesn't move much at all.
2. Trace this original with this bolt (or replace it with a stylus, pencil, etc.) and it 2. Put your original drawing and trace it with a stylus here and it will be radically
will be expanded dramatically on the bottom end of the right leg. reduced at the yardstick joint to the left of here.
3. Notice that the distances (to the two yardstick ends) from here are the same. 3. This bolt remains stuck solidly to the work surface. Doesn't move. Nope. The
Call these holes 'A' yardstick just spins around it a little bit.
4. This bolt always stays in these holes. 4. This bolt never leaves these holes, unless you're feeling very experimental.
5. This set of holes (call them 'B') will be bolted the same distance from the 5. Same ol' same ol'. This bolt (in this configuration) is in the third hole from each
ends as the holes at 'A'. In this case, they're in the third holes from the end of end of the yardsticks.
each yardstick. Choose other sets of holes to alter the amount the original 6. Yep. This bolt is still in the same (third) hole from each end of the yardsticks.
drawing is reduced or expanded.
6. This bolt never moves. Always at this end of the yardstick. Always mounted
solidly to your work surface.
Image Notes
1. Packed for travel. Three feet long, only a few inches wide.
Step 3: Tools You'll Need

Tools:
Drill motor, a 3/8" drill bit (for the bolts) and a 1/2" drill bit (make a hole for the 12mm metal tube that holds the laser) for drilling wood. If your drill motor only accepts bits
up to 3/8", you can buy a bit that drills a 1/2" hole but fits in a 3/8" motor.
A magnifying glass on a homemade stand will come in handy.
Needle-nose pliers. Wire cutter (dikes), ideally that come to a small sharp point. Some screwdrivers will be needed if you'll take apart a DVD burner to get the laser out.
Solder pencil (20 to 30 watt model) and electronic solder. Radio Shack sells number 64-2802 , $8 for a soldering kit with everything you need in one box, even includes
an oversize heat sink alligator clip. If they're out, get a similar kit at Home Depot for $14 in the hand tools section. If the tip on yours is a flat, wedge shape, file it down to
a cone-shaped pointed tip. This transfers less heat (you don't need much, anyway) but makes it possible to get into tight spots. When soldering, you touch the tip to all
the wires at the same time to heat them up, the wires melt the solder, and then get out quickly.
To make the PC board jumper soldering work a little easier, try a Radio Shack Wire Wrap tool 276-1570 and some 30-gauge Wire Wrap wire (red, white, or blue) that
goes with it. It takes a little practice to use the tool to strip the insulation and wrap thin wire around a terminal or wire, then solder them together to the PC board trace. If
you don't like the results, just take the wire off and use a fresh piece. Or, you can buy a box full of U-shaped, pre-stripped jumper wires (Radio Shack 276-173) ordinarily
used for breadboard work.
In fact, if you're sheepish about soldering, you could even use a breadboard (276-175) from the Shack and the pre-stripped jumpers , instead of a PC board. It'll be a little
clumsy, but it should work.
An alligator clip. Radio Shack 270-373 , for more clips than you'll ever need for $3. Or the fat aluminum clip that comes with the solder pencil mentioned above. Or a
small, bent-to-suit paper clip (co-worker's desk, $0) or similar to keep delicate electronic components from being fried alive from the heat of your newly-developed
soldering skills.
Also, clips of any kind to hold on to things for you while you use both hands to solder will come in handy. One hand holds the soldering pencil, the other hand feeds the
solder into the joint. That doesn't leave you with much to hold the pieces you're soldering. You can wedge parts sticking out of the edge of a book to hold them. When you
get tired of that, solder a clip to the end of a piece of stiff wire, and use a wood screw to screw the other end down to a block of wood. Repeat, and you've got two
''Instructables helping hands'' to hold your work.
A brick or flat rock or concrete or scrap drywall or similar for a fireproof work surface (goes under the stuff you're cutting or engraving). Ceramic cookware might be OK,
too. (Neighbor's backyard or mom's kitchen, $0.) Nothing shiny or reflective!
Or, if you can put an air gap under your work, you might get away with a sheet of plywood sitting a few inches below your work. The laser's beam is essentially in an
hourglass shape, with your workpiece situated at the tiny waist of that hourglass. The further you move away from that tiny waist, the weaker the beam gets. Never
underestimate it. It is a silent, serious power tool.
A dark test area so you can check for red light reflections off your work and product surfaces. 'No reflection' is good. (Become a Midnight Rambler, $0.)
Though not required if you follow these directions, a Digital Multimeter can be handy for making sure you get up to, but not over 3.2 Volts to supply the laser, or for
checking polarity, continuity and other things (like unexpected short circuits before they blow something up, instead of after). Get one for under $15 and use it forever, or
this one , or just check on eBay under multimeter .
Some also test temperature (that's not going to work for us -- these temps are WAY too high), or frequency (usually in the audio range - 20Hz to 20,000Hz) capacitance,
transistor gain, have a continuity beeper, etc. You're only going to get one; might as well get the one you want. A 10 Amp range will come in handy some day.
Or, just use the parts I've specified. This design should limit you to no more than 3.2 volts from the power supply, the maximum allowable voltage for many LED lasers.
Any higher voltage on the LED laser lets all the smoke out from the inside and makes it stop working. ;-)
Image Notes
1. These little doodads stick over the ends of the test leads and have little grippers on the ends. That lets you clip them on to connections so you don't have to hold
them. Get a pair at Radio Shack, stock 270-334 for $3.50. Very handy.
2. This Elenco M-1700 digital multimeter is a popular, inexpensive model. Shop around and you can own one for under $20. Search for 'multimeter' on froogle.com or
eBay.com, then sort by price. Radio Shack 22-810 is $20, it takes them 2 days to get one to your local store.
3. You'll use the 20 Volt DC range for your measurements. Don't put the meter on any other range unless you've read the instructions and know what you're doing. If
you do something wrong, you'll probably blow a fuse (inside, by the battery) and have to go to mouser.com or eBay.com to get a replacement.
4. 10 Amp range may come in handy elsewhere. Move the red lead to this hole to use 10A Range. Measure for only a few seconds on this range, then give meter a
few minutes to cool down. I'm serious.
5. Black lead is always negative, common.
6. Red lead is always positive, marked V (omega sign) A, meaning Volts, Ohms, Amperes.
7. This model also measures Capacitance, the gain of transistors, and audio frequencies. You don't need any of that for this project, but maybe in the future . . .
8. Meters always have a power switch. Turn it off when you're done to save the battery.
9. If you've somehow managed to reverse the black and red leads while testing (let's say you put the - lead on the + wire), this number will have a - (minus sign) in
front of it. That means you've got the polarity backwards.
Step 4: Materials You've Gotta Have
Yardsticks
4 yardsticks (Home Depot 611-269, $1.29 each) or any long, thin strips of light, stiff material you can drill through. This will be your pantograph. If you want to shave $5
off your budget, you can get 20" paint stirrers used for 5-gallon paint buckets (free) any place that sells house paint. The shorter length will limit your freedom to make
large stuff easily, but will be easier for small projects. What the hay -- while you're there, get 4 of each.
Or, if you're feeling flush, buy a manufactured pantograph for around $20 . They're sold at woodworking and at art supply stores.
Bolts, Nuts, Washers

4 pieces of 2" long, 3/8" hex-head machine-type bolts (Home Depot 661-899, $0.08 each).
Get 8 nuts (Home Depot 721-842, $0.08 each) and 8 washers (Home Depot 655-570, $0.09 each) to match. Test 'em while you're there -- stuff gets mixed up in the bins.
Parts from Mouser
863-LM350TG Voltage Regulator 3A 1.2-33V (mouser.com, $1.68) adjusts the laser power
532-7128DG Aavid Thermalloy (regulator) Heatsink (mouser.com, $ 0.80) keeps the voltage regulator from burning up
312-9100-500 Slide potentiometer, 500 ohm (2 shown in photo for details, but you only need one, mouser.com, $1.18) adjusts the voltage regulator for the laser power. If
Mouser is out of stock, you can use any 500 ohm potentiometer. If the resistance is higher (e.g., 1000 ohms) the voltage from the power supply can get too high and fry
your laser. When this resistance is at zero ohms, the output is 1.25 volts; more resistance equals more volts output.
660-CF1/4C241J 240 ohm resistor, 1/4 watt (mouser.com, $ 0.10) The color code for the 240 ohm resistor is red, yellow, brown and the 4th and 5th bands don't matter.
Buy 10 and use them for other LED projects.
30BJ250-1.2K 1.2K resistor, 5% tolerance , (1,200 ohms) (not shown in photos below) (mouser.com, $ 0.22) Brown, red, red, gold color code. This resistor shunts
(parallels) the potentiometer to match the resistance perfectly (350 ohms) to limit the voltage regulator to a 3.2 Volt DC maximum. Leave it out and the voltage can go
higher.
441-R332B-GR Inline Fuse Holder (mouser.com, $1.23 and . . .
576-0312001.HXP 1Amp 3AG type fuse (mouser.com, $0.25 each). Get a couple, just in case. I blew my first one by accidentally shorting some clips in my first two
minutes. Fuses are cheaper than parts.
Shipping and handling for these parts from Mouser was under $5 for me.
Lens to Focus the Laser from AixiZ Laser

635nm 5mW laser module 3.2VDC w/ adjustable lens, size 12mm by 30mm from eBay, $15.50 ($12 'Buy It Now' price, plus $3.50 S&H). All you need is the lens and the
short half of the metal tube. Save the laser inside this module for another project, or use it in this project as a low-power alternate.
You'll replace the 5 mW LED laser they give you in the tube with one from a DVD burner.
They've got a couple of different models on eBay, so I've put a photo below from my auction and a photo of what I got. Stickers are different. The sticker I got is much
cooler.
I can't give you a link to the actual auction, since each one they sell has a different auction number. Copy and paste the title, 635nm 5mW laser module 3.2VDC w/
adjustable lens 635 nm in the eBay Search box. (Highlight, CTRL-C to copy, CTRL-V to paste.)
Or, see eBay store for AixiZ Lasers . Seller takes checks or PayPal. PayPal will accept your credit card after you create a PayPal account. As soon as somebody buys
one, they put up another auction.
Or, if an eBay/PayPal purchase rubs you the wrong way, you can call AixiZ in Texas at 1-888-424-9491.
Perfboard
You can get a piece of perfboard (perforated board used to hold soldered items) cheap at Radio Shack. Try 276-159 for $2.29 as it has little let-me-help-you-solder-that
dots on it, or 270-283 for one that's plain, but comes with an enclosure. If the holes are too small to seat the regulator's heat sink, you could cut off the offending tabs, or
ream the holes out with a tiny screwdriver or an old fork tine or point of a scissors or the tip of a nail file (sister's purse, $0). Go slowly, don't break the board.
Fingertip Power Switch

A convenient press-to-operate pushbutton switch, microswitch Radio Shack 275-016 for $2.69 or other switch as you like, to turn the laser on and off effortlessly with your
fingertip. Radio Shack or Mouser.com. You'll have to turn the laser off to move from one part of your work to another, then turn it back on easily. Unplugging the power
supply from the wall over and over is not going to do the job. Do not get a switch that you must press once to turn on, then press again to turn off or you'll soon be
shopping for a better switch.
Pilot Lamps
Some ordinary LED's (Radio Shack, pack of 20 assorted) 276-1622 for $2.59 (don't forget to always use a small resistor (200 to 300 ohms) from mouser.com at 10 for 50
cents, part no. 299-240-RC (any value from 200 to 300 ohms is OK) or get Radio Shack [http://www.radioshack.com/product/index.jsp?productId=2062343&cp 271-1321
5 for $1 and put one of them in series with ordinary LED's or you'll likely blow them up), or a 3 volt flashlight bulb in a socket or any similar indicator to tell you when the
switch to the laser power is turned on. This is for added safety. Remember; when it's on, it burns holes through stuff immediately whether you're paying attention or not.
No surprises.
Solder Support
Some wire wrap wire and wire wrap tool (optional), and/or some stranded, insulated wire Radio Shack 278-1224 , electronics solder, one slightly wet folded paper towel,
some newspaper to solder on so you don't accidentally wreck the dining room table, and an aloe plant in case you get clumsy with your newfound soldering skills. Aloe's
not going to help much if you burn yourself with the laser, so always be careful.
Practice, Patience, Pantograph . . .

Patience to wait four days while your order from Mouser gets there. You'll build the pantograph and touch up your soldering skills while you wait.
Markers
Felt-tip marker or ballpoint pen or a pencil (roommate, $0) to test the pantograph results before you swap the marker for the laser.
Packing Tape
You'll need to secure one (top left end shown) end of the pantograph to your work surface so it doesn't move. Packing tape is OK if it's really secure. The sloppier things
move around, the sloppier your results will be. Drill a 3/8" hole in a scrap block of wood and tape that down if you like, or substitute something you have lying around,
even a heavy book (little brother's Psych 101 college textbook, $0). Also tape the wiring to the yardsticks, etc.
Image Notes
1. This screw-adjustable lens is a critical component.
2. The two pieces of metal tubing screw apart at this line after you peel off the
label. The shorter piece will be used in our project after you remove the low-
power laser inside and a spring that presses against the lens to keep it from
Image Notes turning.
1. 240 ohm resistor, 1/8 watt maximum capacity. Color code is Red, Yellow, 3. The longer tube at the rear, along with the lower-powered laser inside, will
Brown, and the fourth band doesn't matter. Shown here with Red band at the be saved for some other project. Though only one-thousandth of the power of
bottom. our laser, it can still cause eye damage and a very hot light beam. Not a toy.
2. Voltage regulator. Legs (left to right) are VoltageAdjust, VoltageOutput, 4. This is the photo from the seller's eBay auction, to make sure you get the
VoltageInput. Sits inside heat sink shown just above it. correct model.
3. Two potentiometers shown here for clarity, but you only need one. 5. Put toothpick across lens and in this slot and the one across from it to adjust
4. Heat sink for the voltage regulator keeps it from getting too hot and burning the lens by screwing it in or out of the tube.
itself up. 6. Put toothpick across lens and in this slot and the one across from it to adjust
the lens by screwing it in or out of the tube.
Image Notes
1. My (cheesy) photo of the low-power laser and lens I received from eBay
vendor AixiZ. Provided here so you don't think you got the wrong one. Carefully
peel off the "Danger" label and put it on your project to warn others that this is not
a toy, and should be handled seriously.
1. Pry the arm up slightly on the heat sink and slide the regulator under it. I've 1. You'll need 4 yardsticks (or similar) and nuts and bolts to tie them together
hung a resistor on a leg just to show you where it is. Have the plain back of the so they can move smoothly and accurately.
regulator pressing against the flat back of the heat sink. When you're done, the 2. LED laser will go here
two pieces will be locked together for maximum transfer of heat. The heat sink is 3. You'll trace your original drawing with a stylus in this hole and the resulting
now electrically connected to the center leg of the regulator, which is also the output (at left) will be much smaller. If you want to enlarge the output, swap the
output voltage. Don't let the heat sink touch any other electrical connections or it laser with the stylus.
will cause a short, and that could trash your laser, power supply and regulator. 4. This configuration will give massive enlargement or reduction of the original
artwork.
5. This bolt is always mounted solidly to your work surface.
Step 5: Make the Pantograph

This is the 'printer' part of the project. A pantograph lets you copy something without requiring much skill (other than a steady hand). It will enlarge or shrink from the
original, so very tiny or very large projects (and ordinary ones) are easy to copy.
See a pantograph demo here .
You can buy a pantograph at woodworking shops and artist supply stores for around $20, or even less on eBay or through Froogle.com . If you're on a budget (or just
feeling ambitious) you can make one for about $5 out of yardsticks (pick out some flat ones). If your budget is serious, get 4 paint stirrers used for 5-gallon paint buckets
($0) or get one long, thin, stiff strip of wood (father-in-law's garage, $0) and cut it into four equal-length pieces. You'll practice with a marker before you do any laser
cutting, so you'll know if your choice of materials will be acceptable, too heavy, too bendy, too jerky or ???.
You can stack and clamp them to drill holes in them every three inches. If you're doing it by hand without clamps like me, I found I got much cleaner, better accuracy
doing them one at a time and slowly. It's more important that the holes be perfectly round, vertical and clean than it is for them to be perfectly spaced apart or away from
the edge. If the holes are sloppy, your results will be sloppy.
Drill a 3/8" hole in the middle every three inches (a hole at the 3" mark, the 6", 9", etc.) If you decide later that a hole every three inches doesn't work for you for some
reason, just drill more holes.
Get the screws, washers and nuts you got while you were picking up the yardsticks or scavenging the paint stirrers. Later, you can ream a snug fit by just working the
assembled pieces back and forth, or swap bolts to find one that's slightly smaller.
The bolts have a head, a flat length, and a threaded length. The bolt head rides on your work surface. The threaded end sticks up with two yardsticks between two nuts
and washers. If necessary, you can substitute different length bolts to raise and lower the pantograph above your work surface. Lower is more accurate.
When you finish putting the hardware and yardsticks together, put a tiny dab of nail polish (Ask. Don't just go through her purse. That's just tacky) or Wite-Out (co-
worker's desk, $0) on the threads to lock the nut right where you left it on the bolt, yet you can still take it apart later.
Play with the pantograph for a few days with a pencil or a ballpoint or felt tip pen where the laser goes to get the feel of it. Learn to use it to enlarge or shrink your original.
Practicing here will give you better results later.
Get an original of any image you want to engrave or cut later or practice with. Use something simple and get the hang of enlarging or reducing it. Print some words on a
computer printer in large font, copy something from a magazine, etc. and test your results. Practice. You've still got a couple of days before the electronics stuff arrives.
Image Notes
1. Move the 'A' bolt and the 'B' bolt to the middle of their sticks and you get a 2-to-1 drawing ratio. Put the laser on the right and the tracing stylus on the center knee,
and you'll double the size of the original. Switch the laser and the stylus (that is, stylus on the left end and the laser in the middle knee) and you'll get a result that's
one-half the size of the original drawing.
2. Stylus goes here to enlarge. Laser goes here to reduce.
3. Stylus goes here to reduce the size of the original drawing Laser goes here to double the size of the original drawing.
4. This is the 'B' bolt stuck in the middle of the yardsticks.
5. This bolt always remains in these holes.
6. This bolt is always in this hole and always mounted solidly to your work surface.
Step 6: Pick Your Power Supply

This next section on power supplies is a little lengthy. You may be able to skip over most of it, or you may have to read it carefully three times. You already know how
much you know about power supplies.
A wire cutter (in a pinch, there's a crude one on a pair of slip-joint pliers) will cut the wires, and a fingernail clipper will come in handy to very carefully strip insulation off
the ends. A knife has been known to do both, but it's the sign of a newbie.
You'll have a slider potentiometer to continuously vary the voltage from 1.2 to 3.2 volts (low laser power to high power), and a fingertip trigger switch to turn the LED laser
on and off. You should unplug it from the wall when making any changes or adjustments to prevent accidents.
If you want to be totally portable, or you can't scrounge an AC power supply, then use a battery holder and 4 or more AA, C, or D-size flashlight batteries with the voltage
regulator.
Three batteries without a regulator will produce 3.75 volts, about a half-volt too much (rechargeable batteries are 1.25 volts), and you'll probably blow up your $15 laser.
Two batteries without the voltage regulator will give you reduced power. A pair of alkaline batteres will turn out 3+ Volts, nearly full power. A pair of rechargeable batteries
will produce around 2.5 Volts.
One flashlight battery without the regulator will create less burning power, but the focused beam is still dangerous.
"D" batteries last longer than "C" batteries, and "C"s last longer than "AA" batteries. They power the laser, so batteries will go fast at high power. Better yet, scrounge an
AC power supply for full, permanent laser power. See below.
You can get a battery holder at Radio Shack or Mouser.com , or you may already have one. The exact part is not critical, and using batteries makes the whole thing
portable -- it's only an inch or two wide. You can use anything between 4.5 and 32 volts of batteries. That's the input range on the voltage regulator, which will then pump
out between 1.2 volts and 3.2 volts DC for the laser.
You should avoid a common car or motorcycle battery, as those are really overkill, and actually dangerous because they give off toxic, explosive vapors. They can
produce far more than enough current to easily launch your cat at least 10 feet off the ground if he's near (or causes) a short in any wiring, which could then ignite the
explosive vapors. Nasty.
Stick with simple batteries, and don't ever short a rechageable battery -- if you short them out they get red-hot RIGHT NOW and may burst. Alkalines just go dead if you
short them out.
A laptop power supply brick goes for as little as $10 on eBay or search for 'laptop power supply'.
Better yet, if you've got an old 120-volt AC to low-voltage DC power supply (borrow from your brother-in-law and then forget to give it back, $0) laying around from a
laptop, pair of powered speakers, the internal power supply from an old desktop PC (and you don't even have to care if you're using the 12V [yellow] or the 5V [red] line),
etc., that's between 5 volts and 32 volts and is rated 1 Ampere or more (or 1A or 1,000 mA -- it's all the same) you can use that. If it's rated less than 1000 milliamps (mA)
it will still work, it just won't run the laser at full power. You can replace a small one now with a bigger one later. If the power supply output is over 35 volts, it will destroy
your power regulator and your laser. But if it's able to supply over 1,000 mA, it will just run cooler and easier. So, an old laptop power brick rated at 1800mA or at 2.5A
and 18 Volts DC is just fine.
If yours doesn't have an Amp or A or mA rating, it probably lists 'Watts' or 'VA' (Volts times Amps equals Watts). The number of watts should be at least as big as the
number of volts, and both of them should be at least "5" but see the next paragraph for caveats.
Your supply should output at least as many Watts as Volts. So, a 10 volt DC supply that says 10 watts (or 15 watts, or 20 watts) will be fine. But an 18 volt supply rated at
10 watts won't be big enough to run the laser at full power, and you may overheat (and damage) this power supply if you run it hard enough. You might still use it; check it
often for overheating.
If you've got a weird power supply that has an AC output, or rates the output with a ~ (tilde) symbol, don't use it. The squiggly tilde means it's AC, not DC. A tilde on the
120 volt AC input rating is OK.
If you can make up a connector to attach to the end of the power supply's cable (take it with you to Radio Shack) you don't need to destroy the plug on the end if you
don't want to -- you could still use it for your laptop, etc.
You'll need to get the wires (polarity) straight. If you don't have a multimeter, skip the next paragraph.
Set your multimeter to the 20 Volt DC range (or the 200 VDC setting if your power supply is over 20 volts). The red + meter lead, when connected to the positive wire on
your power supply (and the black - lead to the negative wire), will give a normal voltage reading on the meter. If the wires are reversed, there will be a - (minus sign) in
front of the number on the meter. Do not change anything on the meter while it's connected (20VDC to 200VDC and back is OK). Do not use any other range on the
meter until you've read the manual and understand how to use it. If you blow your meter up, don't despair; you probably just blew a fuse inside. Replace the fuse
EXACTLY with one from eBay or Radio Shack -- this is a safety issue.
If you don't have a meter, look at the power supply label, or the case next to the hole where the power supply (used to) plug into the old laptop or whatever. There's
typically a 'circle and tip' drawing of some kind linked to plus and minus signs to signify whether the outside conductor (circle) or inside hole (tip) is which lead. If your plug
has some weird 3-hole arrangement, study it carefully.
If you cut the plug off the end of the wire, you'll notice there are two separate wires side-by-side, (like a lamp or extension cord has) or a single round wire (like a satellite
or TV cable has, only thinner) between the brick and the end in your hand. If there are two wires, one of them is marked with a stripe or a ridge or lettering or something.
That one is usually positive (+ ) and the unmarked wire is usually negative (- )Usually.
If there are two wires and a braid inside, use either wire as long as the ratings show them to be adequate. More voltage in does not equal more voltage out of the
regulator.
If there's only one round wire, you'll find a second wire hidden inside the first. The outside braid wire is usually negative, and the inside wire is usually positive. Usually.
Usually, the positive wire is the one that's marked in some way, and the positive lead on the plug is the one inside. This makes the negative wire unmarked and on the
outside (perimeter) of the plug. Usually.
You can always test the polarity of any low DC voltage with an inexpensive LED connected to a 200 to 500 ohm resistor (the slider you bought is 500 ohms). The LED's
short leg is negative, next to the edge of the plastic that's flattened. If it's backward, nothing happens. Resistor can go on either leg. If it lights, you can determine the
polarity of the wires.
If you still can't figure it out, maybe you should spring a few bucks for the meter, or borrow one.
Enough, already. Let's move on.
Image Notes
1. These ratings say the same thing as the box below. This one says +5V,
Image Notes signifying DC (AC doesn't have + and - leads). The symbols below signifying DC
1. This one is perfect. 5 Volts DC at 1 Amp is what this supply provides as an are the horizontal bar over 3 dashes. This describes that one wire is higher in
output voltage and current. If it said 2 Amps, it would only be working half as voltage than the ground (dashed line) wire, so it's DC.
hard. If it said 10 Volts, it would still be OK, but 32 volts output is the maximum 2. AC Input: works on anything from 100 Volts AC to 240 Volts AC (~ sign) and
for this project. draws four-tenths of one amp from the wall socket. The first DC output is 5 Volts
2. The metal jacket surrounding the plug is the negative terminal (think DC at 1 Amp. The second available output is 12 Volts DC at 1 Amp. Either will
'negative ground in a car'). The hole inside the end (the tip) is the positive work fine, but the 12 Volt side won't have to work as hard; multiply V times A, and
terminal. Unfortunately, if you choose to cut the plug off, you can't tell which the first is 5 Watts. The second is capable of supplying 12 Watts (12 Volts times
wire went where without a multimeter. See text above to determine positive and 1 Amp). The power supply will run cooler with the 12 Volt line, but the voltage
negative wires. regulator will have to remove more volts to get down to 3.2, so that will run hotter.
3. Input is 120 Volts AC at 0.125mA, 60 cycles per second is how often the Use the 5 Volt line if you have this dilemma.
polarity changes. 16VA means 16 Watts. All these ratings are how much power 3. I used the wire in the cord and trashed the rest.
the brick pulls from the AC wall socket. 4. As viewed from the end while you look at it.
4. I used this supply. Meets minimum requirements. 5 Volts at 1 Amp.
Step 7: Laser Stuff
When your laser stuff arrives, read every word in the next section all the way to the end. Out loud. Twice. Don't cheat -- I'm watching you.
This laser will immediately BURN AND CUT anything you put in front of it faster than a hot knife through soft butter. And, a laser is a light beam, so it will REFLECT OFF
OF ANYTHING SHINY OR REFLECTIVE AND THEN BURN WHATEVER ELSE IS NOW IN ITS WAY. You're not going to cut shiny foil or anything else that reflects light
unless you want a quick trip to the Emergency Room. Treat this with the respect you would give any powerful tool.
If it hits your eye, well, you're gonna need that spare you've been ignoring all these years after all.
Keep kids away. This is not a toy, it's an industrial-strength cutting tool that doesn't care one whit what you 'planned' on doing or not doing.
Please don't post comments about something that accidentally got burned unless you really think it will help others avoid the same mistake.
Don't do anything stupid. No drinking. No horseplay. If your friends want to watch and they get a little nutty, just turn it off and wait for them to settle down. If your buddy
wants to try it, well, it's his laptop, right? Don't be afraid to sound a little paternal and give directions and caution to everyone around you. Better safe than sorry.
Pull the power supply from the wall before you make any adjustments or changes, then check your work before plugging it back in again. Unplug it when you're done, or if
you walk away.
Now, go back and read that again. Out loud.
Fortunately, there is a focusing lens that concentrates the full power just in front of the laser. As you move further from this focusing spot, the power spreads out, but it's
still hot. That doesn't mean you can get careless, it just means you may get a second chance. Don't depend on it. Be 100% safe at all times.
For testing and variability of the actual strength of the laser beam, the output voltage of the regulator is adjusted by sliding the the volume-control-slider-like
potentiometer.
The lens screws in an out to adjust the focusing distance to concentrate the entire beam width down to a pinpoint right at the surface of the material to be etched or
burned.
Changing the voltage with the slider alters the strength (brightness) and cutting power of the beam itself, but does not change the focusing distance.
Let's put some stuff together.
Image Notes
1. This was my DVD burner laser. You can see three legs on the right side of this box.
2. This one was the CD burner. See three legs at the bottom of this box.
3. Right-angle mirror shoots the beam upward (into my table).
4. There's a little reflector jobbie in here to coordinate the beams.
Step 8: Assemble the Laser Parts

Study the schematic wiring diagram carefully. Print it out if you can. Download it and expand it if you wish.
Slip the small heat sink over the voltage regulator (see photo). You'll have to pry it open a little with your fingers. Don't bend it too far or it won't be snug on the regulator,
required for good heat transfer. The two will snap into place. You could still damage it if you overheat it, but now it's less likely.
Unscrew the Lens Assembly
Carefully peel off the 'Danger/Laser' label on the AixiZ lens/laser assembly you got from eBay and stick it on your pantograph to alert others that this is not a toy. Or, stick
it to a piece of plastic food wrap and then you can tape it anywhere, or even copy it with your new Laser Cutter / Engraver.
Unscrew the tube with two pairs of pliers (borrowed from the landlord, $0).
Unscrew and remove the black lens housing and the spring inside.
You should now have a long tube sitting on the table, a lens and a spring in one hand, and a short tube with a tiny laser in it. Tear the wires, tiny PC board and white
silicone off the back of the short tube. You'll see the back of the tiny laser. Set the tube up on its end with the laser on the bottom, sitting on the slightly open jaws of the
pliers. The tiny laser was press-fit into the tube. Use a small hammer and a nail set (or a rock and a nail -- I told you there weren't any special tools) to gently pop it back
out. It won't take much force, but this tiny laser is not going to be used on any other project.
You'll put your new laser (scavenged from a DVD burner) in this hole and secure it with epoxy or with a hot-melt glue gun. It must be centered in the hole. Just look down
the tube to see it -- a hands-free magnifying glass comes in handy here.
Image Notes
2. The two pieces of metal tubing screw apart at this line after you peel off the
label. The shorter piece will be used in our project after you remove the low-
power laser inside and a spring that presses against the lens to keep it from
Image Notes turning.
1. Pry the arm up slightly on the heat sink and slide the regulator under it. I've 3. The longer tube at the rear, along with the lower-powered laser inside, will
hung a resistor on a leg just to show you where it is. Have the plain back of the be saved for some other project. Though only one-thousandth of the power of
regulator pressing against the flat back of the heat sink. When you're done, the our laser, it can still cause eye damage and a very hot light beam. Not a toy.
two pieces will be locked together for maximum transfer of heat. The heat sink is 4. This is the photo from the seller's eBay auction, to make sure you get the
now electrically connected to the center leg of the regulator, which is also the correct model.
output voltage. Don't let the heat sink touch any other electrical connections or it 5. Put toothpick across lens and in this slot and the one across from it to adjust
will cause a short, and that could trash your laser, power supply and regulator. the lens by screwing it in or out of the tube.
6. Put toothpick across lens and in this slot and the one across from it to adjust
the lens by screwing it in or out of the tube.
Image Notes
1. There are four solder pads, two positive and two negative. You'll see a tiny
black box at the top. Ideally, you should avoid overheating this box, so you may
solder to the pads at the bottom, even though this drawing shows them at the top.
2. The 1,2,3, numbers are on the pins found on the slide potentiometer.
3. The wires in green carry full current, should be 24 or 22 gauge wire, NOT the
30 gauge used with the wire wrap tool.
4. Push to turn laser on, release to automatically turn laser off.
5. Add cheap LED's from Mouser or Radio Shack. There are lots of colors, sizes,
etc. You only need one 1K resistor for the whole lot. You can use 30 gauge Wire
Wrap wire to connect them.
6. Do not skimp. Get a fuse.
Step 9: Ready to Solder
At this point, you should still be reading all the way through before you begin anything, right?
A hot-melt glue gun will come in handy for semi-permanent mounting of the slide potentiometer, wiring, etc. Just tack tiny dots until you decide on permanent design. If
you change your mind, cut the glue with a knife, peel with a fingernail. or run the glue gun tip over it to re-melt it.
This page is a quick & dirty instructable teaching you how to solder wire. If you're convinced you're a soldering guru, you might skip it, or read it and maybe learn
something valuable.
There are about 12 solder joints formed on 8 components. Take your time, do it right.
You can mount the voltage regulator and resistor components on a piece of perfboard 276-159 from Radio Shack. You might hot melt glue the potentiometer to the board
for convenience.
Solder by following the steps (listed once briefly, then again with detail). If your tip doesn't seem to be hot enough, use a pair of pliers (do not use your fingers -- it's about
700 degrees Fahrenheit) to gently tighten the tip (i.e., screw it down). Sometimes they come loose. Twist too hard, and you'll crack or break the plastic handle.
The smoky fumes given off during soldering are not good for you to breathe, so avoid inhaling them. They won't make you dizzy or anything like that, but they're not good
for you.
0. You may wish to use a Wire Wrap tool 276-1570 and Wire Wrap wire (red, white, or blue) from Radio Shack to make all the low-current connections (those not marked
in Green) and solder them afterward. This includes all resistors and the cheap LED's.
The center and right legs on the regulator need heavier wire, along with both wires to the LED laser. Use 24 or gauge or similar to the wire found in the Power Supply
Brick wiring, perhaps from yet another abandoned power supply.
1. Put the alligator clip on the leg of the voltage regulator, close to the joint you'll make, between the joint and the black body of the regulator.
2. Add a tiny amount of solder to the hot tip to tin it.
3. Clean and roll the tip on the wet towel to wipe off the excess solder and burnt rosin and gunk.
4. Wait 15 seconds for the tip to come back up to temperature.
5. Hold hot tip against both the wires and leg simultaneously for 4 to 10 seconds. No longer. Have the solder pressed against the wires, not the tip.
6. When the wires are hot enough, the heated wire melts the solder. You should not use the pencil tip to melt the solder. This causes an infamous 'cold solder joint' that
will fail later.
Details:
1. Put the alligator clip on the leg of the voltage regulator, close to the joint you'll make, between the joint and the black body of the regulator.
The tiny Radio Shack alligator clips listed are best. If you've opted for the cheapo-cheapo route, bend a paper clip so it clamps on the leg of the regulator somehow.
When you get tired of that, go to Radio Shack and get proper clips. If they're out of the ones I've listed, get any small ones they have (take off any colorful rubber boots).
Technically speaking, if your soldering skills are really up to snuff, you probably won't need the clip at all, because you'll finish the joint quickly, before the body of the
regulator gets very hot. If you're a newbie, clips are cheaper than parts.
Place the body of the part physically lower than the upcoming solder joint -- heat rises.
2. Add a tiny amount of solder to the hot tip to tin it. You don't need a lot of solder. Just enough to liquify anything on the tip so you can wipe it spotlessly shiny in step 3.
3. Clean and roll the tip on the wet towel to wipe off the excess solder and burnt rosin and gunk.
Use a paper towel or napkin, folded down to about a 2 inch square, then get it wet and squeeze the water out. Any time you like, wipe and twist the tip of the pencil on it
to clean off any old solder or burned rosin (liquid rosin inside the hollow solder helps it clean the wires). Don't get cheap about a half-cent's worth of solder; clean the tip
off. Throw the dead blobs away when they cool; do NOT try to reuse them. Solder has lead in it, so behave accordingly. Wiping or using the pencil cools it briefly; give it a
moment to heat up again. Never touch the non-handle part of the pencil (you can feel the heat rising off of it). It will burn you. Bad. Be careful where you set it when
you're not holding it. Make sure pets and people don't drag the cord as they walk by. Don't do it on mom's nice dining room table. Put newspaper down on the floor. And
don't talk with your mouth full. And stop tracking dirt across my nice clean floor! . . . Sorry, flashed back to too many projects made on mom's dining room table.
4. Wait 15 seconds for the tip to come back up to temperature. Don't rush it. Holding the tip above the handle will move the heat to the tip better.
5. Hold hot tip on the wires for about 4 to 10 seconds. No longer. You should have the solder pressed gently against both wires the whole time with your other hand. This
is where those extra clamps come in handy, or anything to hold your work down (tape, a friend, alligator clips mounted to anything, etc.). As soon as the solder starts
melting on the wires, feed in just enough to form a thin layer on the wires (not too much, not a bubble of solder, but a layer is good) and pull away the solder and the
pencil. Don't touch it or blow on it, just leave it alone and still for 10 seconds. If the solder joint looks the same color as the solder in your hand, you're all set. If it looks
gray, grainy or dull, you've got a bad connection, called a cold solder joint. If you fail to get a good solder joint, move on to something else completely different and come
back in a few minutes when this spot has cooled completely and start over. Basically, you're protecting the component from any heat damage by moving around rather
than concentrating on a small area.
6. Touch the solder to the wires so the heated wire melts the solder. You should not use the pencil tip to melt the solder.
That's it. Don't solder multiple leads on a single item (like the 3-legged voltage regulator) all in one pass. Do one, give it two minutes to cool, then do another. Since you
put on the wrap-around heat sink you got for the voltage regulator, that will help, too. Use the alligator clip, too.
Your tip is ready when it's recently tinned, free of excess solder and gunk, and fully heated (5 minutes is fine). Don't forget to unplug it when you're done; it will remain hot
for 5 minutes afterward.
If you find you simply MUST cut some plastic with the hot solder pencil for a project, don't use the very tip; save that for soldering only. Melt plastic just above the tinned
part of the tip. If it doesn't seem to be heating up, tighten the tip gently into the pencil with a pair of pliers.
Heat rises. So, position the black body of the voltage regulator (or anything else valuable) below your solder joint when you apply heat. Solder one lead, wait two minutes;
move the clip and do the next lead. Repeat. Ideally, you'll have a tiny alligator clip clamped on the wire lead, between your prospective solder joint and the black body of
the voltage regulator. The clip will get hot instead of the regulator. Since you'll be excited, you'll forget that the clip is hot and grab it. Go get the aloe plant.
Soldering uses the heat of the pencil to raise the temperature of the wires so they are hot enough to melt solder, but ideally not so hot that the component gets fried.
Then, you touch the end of the solder against the wires and it melts and flows all around everything like an animation you once saw in a bad sci-fi movie. You do NOT
use the pencil to melt the solder. If you just heat the solder with the pencil tip and sort of mash it on to the wires, (reminiscent of trying to stuff clay in your brother's ear), it
won't work.
If you get a wire too hot, anything that's attached to it (insulation, printed circuit board traces, voltage regulators, friend's fingers) will get crisped. You can apply too little
heat (1 to 3 seconds), just enough heat (around 4 to 8 seconds), and too much heat (over 10 seconds). So you've got about 5 seconds to do your work (between the 4-
and 8-second marks). If you screw something up, just move away from that spot for a minute to let everything cool, then try again. No harm, no foul. Take it easy. If two
things get stuck together that shouldn't be or you've got too much solder on something, hold the work up above the pencil tip (again, just for a few seconds) and gravity
will draw the solder down out of the wires and back into the pencil, then clean off the tip on the wet paper towel. Tin the tip with fresh solder and clean it again. Watch for
dripping solder that is trying to land on you. It's still hot.
Practice on lots of spare wire and leftovers from that old radio you've been dying to take apart until you feel confident. Clips of any kind hold things down while you hold
the pencil in one hand and the solder in the other. Wrap wire around the regulator leads to start out with a good physical connection. If you're having trouble, 'tin' anything
you're working with first by putting a little solder on it before connecting it to something else (but this makes wire too stiff to bend - just use a tiny amount of solder to tin
wire, or just tin the very end tip of the wire). Any time you find something that just won't accept solder or 'tin' easily, it's probably dirty or oily. Wipe, clean, file, sand, or
steel wool to a fresh surface, then wipe with a damp paper towel.
So, the drill is this:

Put a clip on the lead right next to the regulator and put the black body of it physically lower than the upcoming solder joint.
Ideally, find something to hold everything in place so you don't have to (see instructables). Wipe the hot pencil on a folded, dampened paper towel to clean it off.
Touch a tiny bit of solder to the tip to tin it and wipe it back off again. It's OK to have just the tiniest amount of solder on the tip to help conduct heat to the wires (like butter
in a frying pan) but add just a little more if you like.
Tin the wire if you like.
Wrap the resistor wire (or the wire connected to the tied-together ends of the potentiometer) around the regulator lead (needle-nose pliers were just made for this).
Apply heat about 4-8 seconds to both the wire and the lead.
Touch solder to the wire and to the leg of the regulator at the same time, but not to the pencil.
Solder flows all around both wires.
Remove solder and pencil.
Let solder joint cool by itself for one minute.
Move the clip to the next wire. Get aloe plant because you grabbed the clip too soon.
Repeat with next connection.
If you look closely at the back of your laser, you'll see one or two tiny rectangular components. One of them is a protection device that shorts out (eliminates) static
electricity jolts that you might accidentally give off while handling the laser PC board. The laser needs around 3 or 4 volts of electricity, not the 10,000 to 20,000 volts that
a static shock contains.
Image Notes
1. There are four solder pads, two positive and two negative. You'll see a tiny
black box at the top. Ideally, you should avoid overheating this box, so you may
solder to the pads at the bottom, even though this drawing shows them at the top.
2. The 1,2,3, numbers are on the pins found on the slide potentiometer.
3. The wires in green carry full current, should be 24 or 22 gauge wire, NOT the 30
gauge used with the wire wrap tool.
4. Push to turn laser on, release to automatically turn laser off.
5. Add cheap LED's from Mouser or Radio Shack. There are lots of colors, sizes,
etc. You only need one 1K resistor for the whole lot. You can use 30 gauge Wire
Wrap wire to connect them.
6. Do not skimp. Get a fuse.
Image Notes
1. Put the voltage regulator LM350TG in these holes. Topmost hole in this photo is
the rightmost leg on the regulator (as viewed from the front label side).
2. One end of the 240 ohm resistor (red, yellow, brown) goes in this hole.
3. One lead of the 1.2K (1200 ohm) resistor (brown, black, red) solders to this
hole.
4. The other end of the 1200 ohm (1.2K) resistor solders here. Stand the resistor
on one end to get it to fit if you didn't get the 1/8th watt size (you'll also have to
bend one side of the heat sink).
5. Before using any PC board, buff it with a steel wool pad or a sponge and
kitchen cleanser to get off any oily residue, then rinse under running water and
dry. If you can't get solder to stick to the copper traces, you probably skipped this
step. Not fun.
6. This hole connects to terminal 1 on the slide potentiometer, which is also
connected to the negative side of the power supply.
7. These three holes hole the negative leads on three indicator LED's.Use wire
wrap wire around one of the legs to jumper for more LED's, if you wish. These are
the 'Power ON' indicator LED's. Use as many LED's as you wish, all connected in
parallel.
8. The fuse holder specified comes with a single piece of wire. Cut it near one end,
strip the wires, and put one wire in this hole. Fuses are cheaper than parts.
9. The positive wire from the power supply, and also one end of the fuse holder go
in these two holes. The holder specified comes with a single piece of wire. Cut it
near one end, strip the wires, and put one wire here. Other end goes to center leg
on the voltage regulator.
10. Expand this hole and let the leg from the heat sink fit here. The other leg on
the heat sink gets bent up out of the way to avoid the 1.2K resistor at the bottom of
this drawing.
11. The other end of the 240 ohm resistor (red, yellow, brown) goes in this hole.
12. Remember when working with PC boards that the view of everything from the
bottom side is the opposite of the view from the top! Take your time, check your
work. Carpenters are taught, "Measure twice, cut once."
13. This board is only one half of what's in the package. Snap off the other half
and use it for another project.
14. A 22 or 24 gauge piece of hookup wire connects this hole to one side of the
Thumb Trigger Switch which carries positive, regulated voltage to the laser.
15. One end of 220 ohm resistor (red, red, yellow) goes in this hole. Supplies
ground lead to the 'Power ON' indicator LED's.
16. You can make jumpers out of the 30 gauge Wire Wrap wire. Wrap it around
the 'legs' sticking through the PC board, then solder all three (wire, leg, copper
pad) together.
17. This pad is where all the negative jumpers and wires meet up. Return wire
from the laser, jumper to the 1.2K resistor, negative power supply lead, jumper to
the top pin on the potentiometer.
18. 240 ohm resistor sits above here
19. 1.2K resistor sits above here, standing up on one of its ends if necessary.
20. Jumper wire goes between this hole and two pins on lower end of
potentiometer. 30 gauge Wire Wrap wire is OK if you wish.
21. This trace carries the negative -- side of the 'Power On' LED series. Short legs
of the LED's can connect to any hole on this trace.
22. Slide potentiometer - one leg fits inside this hole, connects to the other let right
next to it and the PC board trace in the lower left corner of this photo.
23. The other end of the 220 ohm resistor goes here.
24. A ground wire connects here, the other end goes to the large pad of negative
wires at the top of this photo.
25. The long, positive legs on the indicator LED's go in these holes, bend over and
all solder together. Add a jumper wire to the blank copper pad to the left, just
above the voltage regulator.
26. I put more indicator LED's short, negative leads in these holes, then ran a
jumper wire to one of the negative leads 3 pads lower.
27. This hole gets a jumper wire to the long, positive leg on an indicator LED,
directly to the right, to the 9 pads they use. You can use fewer LED's than I did (6).
28. A wire here goes to the trigger switch, to provide current only when the switch
is closed (and the burn laser is on). This lead provides positive power to the
indicator LED's.
29. Jumper wire goes from here to meet up with all the negative wires at top right.
30. A 220 ohm resistor sits above this spot. It provides limited current for the
indicator LED's a little higher than this spot.
Step 10: Adjust the Laser Lens

You should now have a working pantograph. You should also have all the electronic components soldered together. You should also have collected a DVD burner laser
as described by Stephanie Maksylewich
Make a simple gripper to hold the laser on the end of the pantograph. Use a scrap piece of thin wood like one of the paint stirrers or the cut off end of a yardstick. Drill a
1/2" hole in it to hold the laser tube. Since the tube diameter is 12mm, which is slightly less than 1/2", you'll wrap some cellophane tape or packing tape around the tube
to make it press fit into the hole in the wood. Drill a 3/8" hole in the gripper and bolt it to the pantograph, then press the laser into the first hole. You can move this gripper
to the other location on the pantograph to switch from reducing to enlarging your original image. The inch or so that the laser is moved away from the 'ideal' position won't
be enough to affect your finished product, so long as it doesn't rotate around the bolt. Just tape the gripper to one of the yardsticks to keep it stable.
Or, you could just drill a 1/2" hole in the end of the yardstick and use that. Experiment and see which you prefer for your purposes by testing with a ballpoint pen or felt tip
marker placed where the laser would be.
Insert the black spring and screw the lens back halfway in to the end of the laser tube with the slots on the outside. You'll use a toothpick (NOT your fingers or you might
get burned) across the two indents in the end to adjust the lens for maximum effect at the correct distance.
Get your fireproof work surface ready and put a piece of paper or other target on it. Point the laser at the target so you can see the diameter of the beam. This target will
get burned, so use paper or something other than the wall in the dining room. Remember that anything underneath the paper or target will get burned at the same time.
See if you can put an air gap of at least one foot behind the target.
Turn the power on, and adjust the volume-control-like slider to set the power down as low as you can while still seeing it clearly. Turn the power back off.
Use the toothpick across the slots on the side of the lens to adjust the lens. Remember; if you need to change anything, always turn the laser off and then make your
changes. Continue to power on, test for distance, power off, adjust lens, repeat.
Technically, the closer you can get the laser to your work, the more accuracy you'll obtain. Focus just right, and the paper will burn. Just like crisping ants with a
magnifying glass on a sunny day. (No ants were harmed in the making of this instructable.)
Set the focusing distance at about one inch. This will be the distance that the pantograph will hold the laser above your work. Adjust your true working distance with the
length of the bolts holding the pantograph above your working surface and/or adjusting the laser tube in its hole, or where the gripper sits in the stack of yardsticks. You'll
need some gap to be able to see the original image you're copying with the pantograph stylus unless you made your pantograph out of clear plastic or your stylus is at
the very end of the pantograph.
If you find later that you need more clearance (e.g., my fingers are too big, I can't see what I'm doing, I didn't practice enough, uneven work surface, etc.) just replace the
bolts with longer ones and refocus or move the lens in the gripper.
Image Notes
2. The two pieces of metal tubing screw apart at this line after you peel off the label. The shorter piece will be used in our project after you remove the low-power
laser inside and a spring that presses against the lens to keep it from turning.
3. The longer tube at the rear, along with the lower-powered laser inside, will be saved for some other project. Though only one-thousandth of the power of our laser,
it can still cause eye damage and a very hot light beam. Not a toy.
4. This is the photo from the seller's eBay auction, to make sure you get the correct model.
5. Put toothpick across lens and in this slot and the one across from it to adjust the lens by screwing it in or out of the tube.
6. Put toothpick across lens and in this slot and the one across from it to adjust the lens by screwing it in or out of the tube.
Step 11: Put the Pieces Together
You now have the pieces you'll assemble for the finished project.
When you're satisfied, you may wish to press the laser through a piece of plastic food wrap, then put it inside the gripper hole and run a small bead of silicone goop
around the tube where it meets the gripper. This will let you push the lens and tube into the wood, but prevent it from going in too far. The plastic food wrap peels off the
bottom of the silicone so it doesn't stick to the gripper.
Mount the completed wiring, power supply, voltage regulator, (or batteries), and trigger switch with silicone or hot-melt glue. Put as little stress as you can on the
pantograph, since anything that restricts its movement will show up in your finished work.
Practice before you invite all your friends over to show them.
If someone wants to give it a try, unplug the power supply, substitute a marker for the laser and see how they do on a trial run. If they get the hang of it, give them the
safety speech and explain how the power and trigger switch work and see how it goes.
If the party gets out of hand, pull the power supply out of the wall.

1. Indicator LED's 1. Cut and strip the wires to leave enough slack to place the ends wherever you
want. This model is kind of clunky (too large) but the 3AG type fuse it holds is
easy to find.

1. Pin 2 is the slider, so both ends are the same thing. Pins 1 and 3 are at each 1. Indicator LED's show when power is applied to laser.
end of the resistor section, so they are interchangeable with each other. 2. Potentiometer slide varies voltage applied to laser.
3. My fuse holder's wire is too large. If you can come up with a better solution,
more power to ya.
4. This corner of the heat sink gets pried up to avoid a resistor.
5. These wires go the the trigger switch.
6. Negative wire from power supply.
7. Positive wire from power supply.
Image Notes
1. Completed PC board power regulator
2. Jumper wire
3. Negative wires
4. Fuse holder wire connects to VoltageIn leg on regulator.
5. Wire to trigger switch. VoltageOut from regulator.
6. Three LED's have their short leg / flat edge connected here. A jumper wire
goes to the short leg on three more above.
7. These traces are where the long, positive legs go on six indicator LED's,
three above here, and three below.
8. This wire connects to the other side of the trigger switch to provide positive
voltage to the indicator LED's, showing when the laser is powered.
9. Positive wire from power supply, one of the wires to the fuse.
10. These two pins on the potentiometer tie together and to a jumper that goes
to the left.
11. This pin on the potentiometer goes to the negative leads through a jumper
wire.
12. Hot melt glue.
13. The resistors are all inside this box.
14. Center pin on voltage regulator.
Step 12: Burn Some Stuff !

Use good judgement with this project. No flammable stuff nearby, no tricks or horseplay. A fire extinguisher or maybe a towel nearby to throw over any flaming surprise is
a good idea in case things get burning a little out of hand. You might consider disabling it (put the fuse in your pocket) when you're not using it so your little brother or
your nosey roommate doesn't try it out when you're gone.
Ventilate, ventilate, ventilate. There are instructables showing how to make a ventilation system . Or, work in the garage with a door open. Work in front of an open
window with a fan blowing outward. Do something. Don't just breathe that junk.
Put something under your work that won't burn, or you don't care about. A sheet of plywood is disposable, but cheap sheetrock drywall is meant to hold flames down (the
white side, not the paper side). Have somebody at Home Depot show you how to easily score drywall and snap it into small pieces rather than try to cut it. Makes it easier
to get it home, too.
Consider putting a shield between you and the business end of things (that would be the laser beam). If you've practiced with the pantograph, you'll have enough
confidence to trust your results without studying them while you're cutting.
Stuff gets hot. Don't grab things without hovering over them first to test for heat.
Develop good habits. They are what will save you when you have a brain fart late some night.
Ventilate, ventilate, ventilate. Didn't I just say that?
Don't burn anything that might reflect the beam off at some weird angle. If you'll burn through something, make sure there isn't a reflective layer inside it.
This instructable is over. Make your own and share with us.
Have fun. I am.
P.S. Many thanks to Stephanie Maksylewich , who came up with the idea that got me thinking . . .
Image Notes
1. My DVD burner laser attached with hot-melt glue to the lens tube from Aixiz. The copper trace at top right was cut off afterward.
Related Instructables
Laser from dead Pocket-Sized Algebra Tiles by

Laser Flashlight How To Get
computer by Do-it-all multi- frenzy FREE Electronic
Hack!! by Kipkay
smashbob tool Shiny Light Personalize parts! by
(aka Laser) by Your Phone by Plasmana
icinnamon colin
Comments
50 comments Add Comment view all 99 comments
Ssslouter says: Jan 3, 2011. 3:32 PM REPLY

how do I know which leg is VIn, VOut or VAdj? I think I know but I'd rather not take chances.
Hardwyre says: Nov 12, 2010. 1:04 AM REPLY

DVD burner lasers have a max rating of less than 300 milliwatts, how can you claim this will be as strong as industrial lasers?
Is this going to be able to cut stainless steel? Aluminum? At least acrylic and plastic sheet?
Timextoxlive says: Dec 19, 2007. 4:40 PM REPLY

this wouldnt work. Ive made class 3b lasers (a little stronger output than the DVD burner diode). It will SLOWLY cut electrical tape, or light black matches.
but as far a burning anything that isnt thin and black, no chance in hell. sorry man, good idea, but the diode just isnt powerful enough.
hubi says: Aug 20, 2010. 6:01 AM REPLY

This will work, but not for a long time. first mistake, laserdiodes don´t last long if they are voltage driven, it´s better to use a constant current source.
second, a dvd laserdiode from a 16x dvd writer will not last more than 150mA in that case, if properly cooled by a good heatsink or a TEC you can
achieve 250mA. but 500mA or more will cause sudden death of the diode. also laserdiodes don´t like short voltage spikes, they can cause a decrease in
output up to the death of the diode and in your supply there is no protection against those spikes. if you really want to burn morethan only black tape, you
need more power. I used a cheap 2W IR(808nm) Laserdiode with constant current source. to see the beam for focussing, one can use a digitalcam.
carlos flores says: Sep 19, 2010. 12:06 PM REPLY
Estimado HuBi no entendi bien lo de la camara pudieras extensor digital Mas El tema
yespotato says: Jul 10, 2010. 8:12 PM REPLY

it does work i did it.
covey12 says: Apr 17, 2009. 11:25 AM REPLY

ive used dvd lasers to burn everything from balloons to balsa wood
Ssslouter says: Aug 24, 2010. 5:12 PM REPLY

would it be able to cut cardboard?
shubham garg says: Aug 8, 2010. 5:23 AM REPLY

What are the things that can be burned with the laser cutter as this?
pufferfish9108 says: Mar 31, 2010. 1:26 PM REPLY

how do u do the dvd burner thing? is there a link?
Armchair Pyro says: Jul 24, 2010. 9:46 AM REPLY

first page where it says "Stephanie Maksylewich" 1) click on it 2) hover mouse over "high-tech stuff" 3) then "lasers" 4) then click on "DVD Laser" or
similar
PainTrane says: Jun 7, 2010. 10:07 PM REPLY

Could I use a 6V battery to power this laser? He stated that the laser only uses 3.2V max. So would a 6V battery dropped to 3.2V work okay? Thanks.
WV_Kokamo_Joe says: Apr 9, 2010. 7:17 PM REPLY

I want to say to i m legend that YOUR Comment on this man's hard work is very rude and I think is not positive or constructive. Lets See your small
converging lens on your laser cutter. anyone else want to see it? I know I do.....
rhino21 says: Jan 25, 2010. 11:07 AM REPLY

Is there any way to protect your eyes or rest of your body from the laser burning you or blinding you? Would a welding mask work?
mmcnickle says: Feb 25, 2010. 9:43 AM REPLY

Welding mask is no good.
You need to buy the correct laser googles i.e. the googles match the wavelength of the laser you are using.
ttrat says: Mar 19, 2010. 3:36 PM REPLY

lol "googles"
rhino21 says: Feb 25, 2010. 11:08 AM REPLY

OK. Cool. My dad just told me he has some laser goggles. Thanks!
iBurn says: May 28, 2010. 10:32 AM REPLY

They won't work if they're not made for the same wavelength as the laser they're supposed to protect you from.
kNeXFreek says: Jan 21, 2010. 5:42 PM REPLY

AWESOME!!!!!!
thingygoboom says: Dec 13, 2009. 8:49 PM REPLY
An incredibly good idea and Instructable.
However I don't trust myself working on anything like that.
madgyver says: Jul 11, 2007. 2:39 PM REPLY

What's been said about the laser and its output so far is quite right. The Laser will not be able to "cut" anything thicker then 0.25mm.
Here you can see mine:

http://www.youtube.com/watch?v=wXfRSjHgtxs
But it shoud be nice or engraving stuff, if you move and hold it precise of course.
drcrash says: Jul 14, 2007. 8:39 AM REPLY

Would a DVD laser cut foam? (Like pink or blue extruded polystyrene insulation foam?) That could actually be very useful; if you can cut a shape in
foam, you can easily mold and cast it, or put a hard surface on it and vacuum form over it. Foam is a bunch of thin-walled bubbles, so cutting through it is
like cutting through a bunch of very thin layers of plastic separated by air. I don't know whether to expect that to work, though. I don't know if the
frequencies put out by DVD lasers are absorbed well by the plastics that foams are made out of. (And maybe not---I guess they're designed to pass
through the polycarbonate plastic that DVD's are made out of. Unless polystyrene has an absorption peak there, where polycarbonate apparently
doesn't, the laser beam may just go through a bunch of layers without cutting any of them.) I notice that on your YouTube video, you're engraving a dark-
colored plastic. Does it work with light-colored plastic, or does to much of the beam pass through or reflect off?
quasi44 says: Nov 10, 2009. 8:21 AM REPLY

With a foam, the integrity of the beam is compromised from the shape of the mildly refracting surface of the bubbles in it, causing near instant heat in
an area where random gases are expanded with the beam, causing little mini explosions that subtract from the accuracy of the cut before the beam
actually gets there. Nothing wrong with your idea except choice of medium for your mold.
madgyver says: Jul 18, 2007. 7:47 AM REPLY

The Laser will cut foam, but it will also take a lot of time. Doing it with a knive is faster und more precise. The laser melts and then burns ist away.
Real laser engravers use lasers, so powerfull they actually vaporise material away, yielding a nice and clean cut. Indeed those laser only work on
dark plastics and dark woods.
Rybin says: Aug 24, 2007. 5:03 PM REPLY

so what would it take for me to make a hand-held laser cutter that can penetrate say... 1/8" corrugated steel? just curious...
quasi44 says: Nov 10, 2009. 8:05 AM REPLY

The problem with a laser is that for it to be useful, you must be able to both contain, and control it. Lasers can be optically pumped using very small
amounts of power to near limitless coherence...provided your lenses and mirrors are made precisely enough, and placed precisely enough....but then
you MUST be able to provide an environment for it, free of stuff like dust, flammable gases like oxygen and hydrogen, and the mirrors; not precisely
equal, one of them must allow the pumped beam pass...understand, people, lasers are neat, but be VERY serious when experimenting. The
consequences are.
PikminRed says: Nov 8, 2009. 5:47 PM REPLY

"When your laser stuff arrives, read every word in the next section all the way to the end. Out loud. Twice. Don't cheat -- I'm watching you. This laser will
immediately BURN AND CUT anything you put in front of it faster than a hot knife through soft butter. And, a laser is a light beam, so it will REFLECT OFF
OF ANYTHING SHINY OR REFLECTIVE AND THEN BURN WHATEVER ELSE IS NOW IN ITS WAY. You're not going to cut shiny foil or anything else that
reflects light unless you want a quick trip to the Emergency Room."
Lol I'm Still following your warnings but. That. That was funny.
jordan98 says: Nov 4, 2009. 3:54 PM REPLY

the pick your power supply page is doing the same
jordan98 says: Nov 4, 2009. 3:53 PM REPLY

could you please put a list of the materials and tools needed in the intro because whenever i try to view them it shows but the text that you put in is missing
rrp9 says: Oct 16, 2009. 8:35 AM REPLY

This is an excellent instructable. I just have one comment: If you place a stylus or laser in the lower middle joint as shown, the only motion possible at this
point is to swing back and forth in an arc. Because one of the segments is pinned at the other end, swinging (rotating around the pin) is all it can do....
rrp9 says: Oct 16, 2009. 8:48 AM REPLY

Oops! After looking at this a little further, I must qualify my previous comment. This IS a good instructable in the level of detail, instructions, etc.
However, it is not a functional device as designed. Laser cutting with bolts through yardsticks just will not work. Hence the lack of any photos of the
assembled and functional device or any samples of its output....
Briguy9 says: Jul 16, 2009. 7:20 PM REPLY
ah, the pantograph, a century-old invention. changing something like this that's tried and true would be like trying to reinvent the wheel, right?
omnibot says: Sep 9, 2009. 2:25 PM REPLY

Actually there are some new types of wheels out there like the Mecanum and Omni wheel. Also there is a square wheel:
"A different type of square-wheeled vehicle was invented in 2006 by Jason Winckler of Global Composites, Inc. in the United States. This has square
wheels, linked together and offset by 22.5°, rolling on a flat surface. The prototype appears ungainly, but the inventor proposes that the system may be
useful in microscopic-sized machines (MEMS)."
Tommyhzy says: Aug 8, 2009. 3:14 PM REPLY

Step 9 and 10: HOLY EXCREMENT that is a LOT of typing. 5 stars because you put so much time and dedication trying to teach other DIYers how to save
about $6000 and get a nice milkshake :)
matroska says: May 28, 2009. 11:15 AM REPLY

Wow! This instructable was the missing part for my laser etcher project! I was too planing to build a DIY laser etcher machine, only mine would be computer
controlled. However I knew nuts about lasers, and I really wasen't sure a DVD burner diode could do the job. I even had no clue about how to supply it. Well,
now it's solved! I have an old PC power supply, with many output ratings, varying from 1A to 15A (!), and from 3.5V to 12V, however I wouldn't know how to
use it. I also have an old laptop adapter, rated around 17V I think, I forgot the amperage. I do have a question... how it is possible to supply, say the 12V you
mentioned, if the diode will burn out at more than 3,25V? Other than this, thank you, you are a true genious and my cheap DIY will be done with your help :)
MaddMann says: May 21, 2009. 11:44 AM REPLY

I don't know enough about it to say whether or not it will burn anything, but I'm going to give it a try anyway; the diode burns DVD's why not paper, wood,
etc? Increasing its intensity with a magnifying/focusing lens can only help. If it does work I'm thinking I'll build a CNC from one of the Instructables and slap
this laser into it - set it and go! I'm also thinking that some protective laser safety goggles formed around the base of the laser would greatly increase the
safety of this. Nice instructable, by the way!
cuchulain92 says: Apr 23, 2009. 2:57 PM REPLY

Has anyone considered focusing the beams from multiple emitters to a single point?
Rayl12 says: Mar 6, 2009. 7:33 PM REPLY

Just out of interest guys, have any of you seen the Reprap http://reprap.org/bin/view/Main/MakeYourOwnRepRap
Noodle god says: Jan 31, 2009. 10:34 PM REPLY

How many mw's is this?
bombmaker2 says: Jan 6, 2009. 2:14 PM REPLY

I'm going to build this but hook up a joystick controlled table

As labeled in the picture, the pantograph can't work. The cutter can only move in an arc, not trace out arbitrary shapes. (A picture of the whole system---fully
assembled, properly labeled, and working---would be a good thing.)
dchall8 says: Jul 2, 2007. 11:22 AM REPLY

I would like to see the entire assembly, too. But what are you saying about a pantograph not working to trace arbitrary shapes? The pantograph I had as
a kid seemed to trace out anything I put under it.

Pantographs certainly do work; they're great. They work in 3D too, if you have one that doesn't flex out of a plane, and attach it to the table (or stand
or whatever) with a universal joint. (That's where the great potential of pantographs lies. The Sears Crafstman Deluxe Router Pantograph will do 3D
shallow reliefs, but that's just scratching the surface, so to speak. In the 19th century people used 3D pantographs and synchronized turntables to
scale sculptures up and down, in the round. Cool.) The picture says that the cutter is attached at the opposite end of the same lever from the pivot
that mounts to the table. That is wrong. If you do it that way, the cutter will always be the same distance from the pivot---it can only move in a circle,
not toward or away from the pivot. For a pantograph to work, you have to mount the cutter on one of the other levers, in a straight line between the
main pivot and the probe. (Or to scale things up, with the probe between the cutter and the main pivot, but also in a straight line.) It'd be good if the
instructable had a (correct) explanation of how a pantograph works, or at least a link to one. (There are several on the web. One has a Java applet
that lets you play with a virtual pantograph in your browser.)
dchall8 says: Jul 2, 2007. 3:28 PM REPLY

I see. You were pointing out that the pictures were labeled incorrectly.
drcrash says: Jul 2, 2007. 5:32 PM REPLY
Right. But I have my doubts that a pantograph will work with a laser. My impression is that you need to move the beam very precisely and at a
very precise rate. If the beam is bouncing around significantly, moving at variable rates and so on, it'll cut through in some places, and just
wobble back and forth making shallow cuts in others. Generally, you need precision movement comparable to the size of your cutter. Laser
beams are very small and sharp. (Or if they're not, they require boatloads of power to actually cut anything.) I find it hard to imagine getting
the necessary precision from levers made out of yardsticks, or enough power to cut a wide swath from a DVD burner laser.
reginaron says: Oct 5, 2007. 9:27 AM REPLY

Hi there. Im looking for type of laser that will cut through frozen (mostly pasteries) food. Knives are too slow and messy. Know of any
links.. thanx rr
ReCreate says: Dec 13, 2008. 5:33 PM REPLY

i think since it is ice it will reflect and burn your eye out
jongscx says: Nov 25, 2008. 11:00 AM REPLY

if it's frozen, try a band saw
drcrash says: Aug 1, 2007. 2:41 PM REPLY

And the picture is STILL wrong.
LasVegas says: Jul 2, 2007. 2:22 AM REPLY

I'd also like to see the completed project and examples.
view all 99 comments

60$ Laser Engraver - Cutter - Instructables

Uploaded by

Copyright:

Available Formats

60$ Laser Engraver - Cutter - Instructables

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

60$ Laser Engraver - Cutter - Instructables

Uploaded by

Copyright:

Available Formats

Home Sign Up!

Browse Community Submit

$60 Laser Engraver / Cutter

$60 Laser Engraver / Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: $60 Laser Engraver / Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: First things first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2: Rough Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Tools You'll Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 4: Materials You've Gotta Have . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 5: Make the Pantograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 6: Pick Your Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 7: Laser Stuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 8: Assemble the Laser Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 9: Ready to Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 10: Adjust the Laser Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Step 11: Put the Pieces Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 12: Burn Some Stuff ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Step 1: First things first

Use common sense, and safety first.

Let's engrave some stuff!

Build a DVD burner laser as Stephanie shows.

Image Notes Image Notes

Step 3: Tools You'll Need

A magnifying glass on a homemade stand will come in handy.

Bolts, Nuts, Washers

Parts from Mouser

441-R332B-GR Inline Fuse Holder (mouser.com, $1.23 and . . .

Lens to Focus the Laser from AixiZ Laser

Fingertip Power Switch

Practice, Patience, Pantograph . . .

Step 5: Make the Pantograph

See a pantograph demo here .

Step 6: Pick Your Power Supply

Enough, already. Let's move on.

Now, go back and read that again. Out loud.

Let's put some stuff together.

Step 8: Assemble the Laser Parts

Unscrew the Lens Assembly

2. Add a tiny amount of solder to the hot tip to tin it.

4. Wait 15 seconds for the tip to come back up to temperature.

So, the drill is this:

Step 10: Adjust the Laser Lens

Image Notes Image Notes

Image Notes Image Notes

Step 12: Burn Some Stuff !

Ventilate, ventilate, ventilate. Didn't I just say that?

Have fun. I am.

Laser from dead Pocket-Sized Algebra Tiles by

Ssslouter says: Jan 3, 2011. 3:32 PM REPLY

Hardwyre says: Nov 12, 2010. 1:04 AM REPLY

Timextoxlive says: Dec 19, 2007. 4:40 PM REPLY

hubi says: Aug 20, 2010. 6:01 AM REPLY

yespotato says: Jul 10, 2010. 8:12 PM REPLY

covey12 says: Apr 17, 2009. 11:25 AM REPLY

Ssslouter says: Aug 24, 2010. 5:12 PM REPLY

shubham garg says: Aug 8, 2010. 5:23 AM REPLY

pufferfish9108 says: Mar 31, 2010. 1:26 PM REPLY

Armchair Pyro says: Jul 24, 2010. 9:46 AM REPLY

PainTrane says: Jun 7, 2010. 10:07 PM REPLY