Overview
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Feeling limited by the size and time limitations of 3D printing as well as environmental concerns, I realised I would benefit from adding a large format laser cutter to my resources. I have a very limited work space and so I decided to design an arrangement that could fold away. This goes against the standard design of laser cutters which are rigidly fixed in place. To compensate for this I would need to implement several forms of calibration into the design. Long term I hope to release this design as a form of open source hardware.
CAD Design and 3D printing
I started by creating sketches of the overall design and how I wanted the frame to fold and fit together. I intended for every piece to be 3D printed, laser cut or made from industry standard parts to keep costs down. I then designed it in fusion 360. One of my aims for the project was to keep the design scalable so that it can be easily adapted for different cutting areas and needs which led to this modular design.
Sheet Metal Design
Once the initial proof of concept prototype model was made I started work on the second version that used laser cut sheet metal as the primary material. This would increase the strength of the design and reduce the cost of manufacture. I first prototyped every part in pink perspex.
Open Source Hardware
My design is targeted at hobbyist makers and is therefore perfect for releasing into the open source domain. Due to its collapsible nature it is unlikely to get the accuracy of conventional laser cutters but compensates for that through it's small form factor and scalable design. I kept the design in line with open source standards, all components can be purchased as standardised parts or created from the open designs.
Safety Considerations
Laser cutters come with several health and safety considerations that needed to be considered carefully before moving forward with this design. The design has a large sheet of laser proof acrylic that surrounds the cutting area. This protects the user from the blinding light while also allowing for full visibility of the workspace. This acrylic tube also connects to an extractor fan to reduce the potentially toxic fumes. There is also a large emergency cut-off switch in the event of fire or other safety risk. Even with these precautions it is still only to be used with safety goggles and in well ventilated areas.
Iterative Design
Iterative design is a key part of any large project. The first prototype was simply a proof of concept to see if I could get a reasonable resolution on a collapsible frame as well as to personally gain experience in the technology required. Once I had assured myself that it was possible I moved on to a second design that would improve on the first. 3D printed parts have been swapped for laser cut sheet parts to improve strength. Drag chains are to be used to hold all the cables away from the workspace and while the design is still modular, some of the wiring connections have been simplified to improve reliability.
