Laser-cutter-user-guide

Shop Area: Rapid Prototyping Tool: CO2 Laser Cutter Requires in-person training: Yes

Procedure Number UG 120-02, Rev. 1

Date 1/28/2021

GENERAL

Good-ol-laser

This guide is for the 100W ShenHui and 150W Boss CO2 laser cutters. 

These CO2 lasers cut leather, non-synthetic textiles, acrylic, wood, and other non-metal materials. In a CO2 laser cutter, the laser beam is created in a tube filled with CO2 gas. Next, with the help of mirrors and lenses, the laser beam is directed to the laser head and focused on the material surface. Electronically controlled motors move the laser head to cut or engrave the desired shape into the material of the workpiece. The shape is defined by an input file which can be a vector or raster image. When the laser hits the material, a very small area is heated in an extremely short period, causing the material to melt, burn or vaporize.

In general, there are two tasks that a laser cutter can perform: Cutting and Engraving.

We use LightBurn as the software for controlling the laser. The general workflow is to draw something in a program like Inkscape or FreeCAD, save the drawing as an svg or dxf file, then import the svg or dxf file into LightBurn. Lightburn is then used to control power, speed, and cutting operations before sending the job to the laser cutter. Simple designs can be created within the LighBurn software, skipping the Inkscape/FreeCAD step.

SAFETY

• The lasering process may generate smoke and gasses that can harm you and damage the machine. Note that materials such as PVC and Vinyl create a corrosive chlorine gas and are prohibited.
• Lasers are a fire hazard. Keep extinguishers close and NEVER leave the machine unattended.
  • All materials are flammable, don't walk away mid cut.
• Close the lid before sending your file to the laser. The lid is not meant to be leaned on and cannot support body weight.
• Do not lean on the honeycomb bed platform inside the machine. The honeycomb platform is not strong enough to support body weight.
• Do not remove material from the cutting bed before it has cooled.
• Clean up clutter, debris and flammable materials in the laser cutter after use. 
• Do not look directly at the laser beam.
• The high intensity laser beam can produce extremely high temperatures and significant amounts of heat as the substrate material is burned away while cutting.

REFERENCE

• LightBurn Video Tutorial: https://www.youtube.com/watch?v=KdqMW3F_iIU
• Boss laser settings: https://bosslaser.com/laser-settings/
• Boss laser Operator's Manual: Boss Laser User Manual
• Boss laser Quick Start Guide: Boss Laser Quick Start Guide

PROCEDURE

1. Prepare Workpiece
   1. Turn on the laser cutter using the large rotary switch. The laser head will automatically home to the corner of the machine.
   2. Set your workpiece on the laser bed.
   3. Use the control panel arrow keys to drive the laser nozzle to your workpiece.
   4. Adjust the bed height using the U-axis controls or the nozzle height using the Z-axis controls. Set the nozzle distance from the material to the appropriate focal length, based upon signage on the machine. This gap is typically close to 15mm.
   5. Ensure that the X and Y position of the nozzle is at the origin position that you desire.
2. Prepare Software
   1. Launch the LightBurn application.
   2. If LightBurn prompts you for a license key, you can find the key in /vsfs01/share/LIGHTBURN_LICENSE
   3. Import your design by File->Import or open an existing project by File->Open.
   4. A list of operations will populate the upper right hand window (Cuts / Layers) based on the colors detected in your design. The next step is to set each of these operations to perform what you desire. Double click each operation and set the type (cut vs fill), the power, and the speed. This is also where you can set more advanced settings like perforation, line spacing, and line angle.
   5. Select the appropriate machine name under the Devices dropdown window at the bottom right.
   6. Preview the job by click Frame at the center right of the screen. This will move the laser nozzle to show the bounding box of your job.
   7. Click Start to start the job.
3. Shut down
   1. Once your job is finished, make sure to clear the laser bed of any debris.
   2. Turn off the large rotary switch.

Materials that can be cut or engraved with a laser.

Material	Cut	Engrave	Comment
Wood	x	x
Plywood	x	x	Lasers can struggle to cut plywood sheets with exterior glue. Use plywood with interior glue.
MDF	x	x
Cork	x	x
Cardboard	x	x
Paper	x	x
Leather	x	x	Use vegetable-tanned for best results
Felt	x	x
Cotton	x	x
Acrylic (Plexiglas)	x	x
Delrin (POM, acetal)	x	x
High-density polyethylene (HDPE)	(x)	(x)	Edges melt badly. Watch closely – easily catches fire.
Polypropylene (PP)	x	x	Melts somewhat
Granite		x
Marble		x
Slate		x
Stone tiles		x
Ceramic, Porcelain		x
Glass		x
Stainless Steel		(x)	Can be marked
Aluminum		(x)	Can be marked

 

Materials that should NOT be cut or engraved with a laser.

These materials include (but are not limited to):

• Artificial leather that contains chromium (VI)
• Carbon fibers (Carbon)
• Polyvinyl chloride (PVC)
• Polyvinyl butyrale (PVB)
• Polytetrafluoroethylenes (PTFE /Teflon)
• Beryllium oxide
• Any material containing halogens (fluorine, chlorine, bromine, iodine and astatine), epoxy or phenolic resins

Rotary Engraving

The laser cutter can perform rotary operations using the U-axis. The general procedure is as follows:

1. Plug the rotary engraver into the inside, right wall of the laser.
2. Navigate to Tools > Rotary Settings. Click the Enable Rotary button and set either the Object Diameter or Object Circumference to match your part's dimensions.
3. Use ‘Start from current position’ in Lightburn
4. Jog x and y on the control panel to move the laser to the required starting point on the work
5. Press ‘Origin’ button on the control panel
6. Send job (not start) from Lightburn to laser
7. Load file from control panel by pressing File -> filename. Then run job by pressing start button on control panel.
8. DO NOT FORGET to disable rotary when finished. Tools > Rotary Settings, deactivate Enable Rotary. Otherwise the machine will not work for the next person.

TROUBLESHOOTING

• If your parts are dimensionally inaccurate, LightBurn is setup to read dxf files in units of inches, so make sure to select inches when exporting from your design program.
• If regular shapes are being engraved or cut as irregular (i.e. circles are coming out as ovals), there's likely something wrong with the drive belts, probably tension
• If laser performance is poor, the lens may need to be cleaned:
  • Ensure you have all the proper cleaning materials:
    • Lens Cleaning Paper
    • Cotton Swab
    • Liquid Lens Cleaner
  • There are two mirrors and one lens that direct the laser beam. One of the mirrors and the lens are located on the part that moves around and cuts, the other mirror is on the far right end of the arm.
  • To clean the lens, fold some Lens Cleaning Paper, do not touch whatever part of the paper you intend to clean the lens with. One or two drops of a liquid lens cleaner on the paper, and wipe the lens off. If the paper comes out dirty, get a new piece of paper and repeat the process. When the paper is no longer dirty, the lens is clean.
  • Use a cotton swab for the mirrors. Brush off your mirrors with it, and check the swab for dirt. If you see dirt repeat the wiping until no more dirt/dust comes off.
  • The mirror that's far away from the lens doesn't need to be cleaned as often, as it's not in direct line of the cloud of material smoke being created by the laser.
• If smoke is not venting out through the back of the machine, the exhaust hose may need to be cleared:
  • At fan unit near window, remove wooden cap from Y shaped exhaust port.
  • Use provided brush to clean out exhaust port.

                                             END OF THE PROCEDURE