Digital fabrication instruments can run from lots of to many tens of hundreds of {dollars}. For makers taken with a very useful gizmo at a comparatively low preliminary price with great improve potential, the generic “K40” kind 40W CO2 laser platform is tough to beat.
Considerably extra highly effective than diode lasers, K40 lasers can reduce wooden, leather-based, acrylic, paper, and a variety of different supplies (usually as much as about ¼” thick, although that varies by materials). It is going to engrave on many extra kinds of materials, although struggles with steel engraving. Whereas extra highly effective (and costly) lasers can outperform these capabilities, the K40 will be considerably improved with end-user upgrades. In virtually all instances, making use of each improve out there to a K40 nonetheless leads to a cheaper instrument than shifting as much as a 50W or 60W laser.
For makers prepared to maneuver past diode laser options, the K40 is a enjoyable, inexpensive platform prepared for modification. Listed below are my suggestions, primarily based on upgrades I’ve carried out to mine.
OMTECH K40
Should you’re going to improve a K40, you might want to begin with a K40. I bought mine from OMTech, a U.S.- primarily based firm that provides worth to the acquisition of the final K40 mannequin (for a value after all) by checking the standard of construct, elements, and so on. Cheaper, almost similar models are straight importable, however typically have element or construct challenges. This unit is completely useful out of the field, however the platform can also be an ideal base for upgrades.
- Value: $450, Return on funding (ROI): 8
- Ease of set up (1=poor, 10=wonderful): 8
- Directions
- Advice: TOTALLY NECESSARY!
3MA ANALOG METER
That is an important improve. The inventory models report energy as a share of energy provide capability, however this varies from machine to machine. To have the ability to use chopping or engraving settings from different folks, the precise amperage must be used, and a meter is required to have the ability to discern it.
- Value: $10, ROI: 10
- Ease of setup: 4
- Directions
- Advice: MUST DO
SAFETY GLASSES
CO2 lasers are usually not seen to the human eye. You possibly can’t inform if backscatter from the beam is inflicting harm till after it’s occurred. The lid of the K40 has a tinted panel that serves as a filter, however everytime you’re aligning mirrors or doing different operations that want to fireplace the laser whereas the lid is up, applicable eye safety is important. The wavelength that the K40 CO2 laser emits ranges from 10,400–10,600nm; glasses rated at 10,600nm are probably the most available.
- Value: $45, ROI: 10
- Ease of set up: 10
- Advice: MUST DO
LIGHTBURN SOFTWARE
LightBurn is a full-featured laser controlling package deal. Whereas quite a lot of useful freeware packages like K40Whisperer are completely usable, LightBurn gives many extra options that make it well worth the license charge. LightBurn requires an upgraded controller board (e.g. the Cohesion3D LaserBoard listed under) to work with a K40.
- Value: $60, ROI: 8
- Ease of set up: 10
- Directions
- Advice: NICE TO DO
COHESION3D LASERBOARD
The inventory K40 controller board can’t differ laser energy, so it will possibly’t do precise grayscale photographs — it solely does dither-type “grays.” It additionally limits the software program that can be utilized. A wide range of after-market controllers can be found, with the Cohesion3D LaserBoard arguably the most well-liked. This Smoothie firmware-based board helps exterior shows/controllers, grayscaling, rotary axis instruments, air-assist relays, and superior software program packages like LightBurn.
- Value: $230, ROI: 7
- Ease of set up: 4
- Directions
- Advice: NICE TO DO
LIGHTBURN CAMERA
This digital camera mounts within the lid and works with the LightBurn software program to permit an image of the fabric on the chopping mattress for use within the software program to orient and place the photographs and features to be engraved or reduce. It’s not important, however as soon as you utilize it, you’ll by no means ever wish to return to different registration strategies. It comes as a skinny PCB; I printed an enclosure for mine.
- Value: $80, ROI: 8
- Ease of set up: 5
- Directions
- Advice: NICE TO DO
LID STAND
The K40 lid will relaxation within the “far again” place (about 15° previous vertical,) however given a bump or robust wind, it will possibly come crashing down. This isn’t a giant downside, however utilizing a lid stand positively feels safer.
- Value: $0, ROI: 10
- Ease of set up: 10
- Hyperlink to half: Scrap materials and 3D printed (or laser reduce!) elements
- Advice: NICE TO DO (MUST DO if utilizing LightBurn digital camera)
NOTE: To make use of the LightBurn digital camera, you might want to have the lid positioned constantly at about 60% of full open. I addressed this by chopping a chunk of ½” angle aluminum and 3D printing ends that match on the K40 base and lid. After I wedge open the lid with it, I do know it’s within the appropriate place for the digital camera.
CROSSHAIR LASER SIGHTS
With out one thing just like the LightBurn digital camera, laser crosshairs to visually show the place the beam will hit are an ideal support in positioning materials.
- Value: $8, ROI: 7
- Ease of set up: 4
- Advice: NICE TO DO
AIR ASSIST HEAD
This gadget replaces the inventory head (or simply the underside of it), permitting a supply of compressed air to shoot down alongside the laser beam. This suppresses flames and the ensuing char that the laser causes with many supplies.
- Value: $25, ROI: 8
- Ease of set up: 9
- Directions
- Advice: SHOULD DO
AIRBRUSH COMPRESSOR
For air, there are a selection of heavy responsibility aquarium pumps and different choices. I purchased an airbrush compressor since it is usually helpful for portray.
- Value: $65, ROI: 5
- Ease of set up: 7
- Advice: MUST DO (some resolution if utilizing air-assist)
EXHAUST SYSTEM
The inventory exhaust fan is simply barely in a position to clear smoke and fumes from the laser. A extra highly effective fan is a giant win to maintain from stinking up your store and accumulating residue in your mirrors and lens.
- Value: $60, ROI: 8
- Ease of set up: 7
- Hyperlinks to elements: 1, 2, 3, and 4
- Advice: SHOULD DO
Z-HEIGHT LAB JACK
By eradicating the static deck supplied with the K40, you possibly can put a height-adjustable desk instead. That is essential as a result of the focus of the laser by no means adjustments; as an alternative, you progress the fabric up and all the way down to accommodate completely different thicknesses. This jack’s desk floor is simply 4″×4″, so it wants one thing on high of it. It’s straightforward to unintentionally tilt the highest, so use a degree to verify it’s true to the laser’s X and Y axes.
- Value: $20, ROI: 8
- Ease of set up: 6
- Advice: SHOULD DO
LENS
It is a drop-in substitute for the inventory focus lens that has higher coatings and efficiency.
- Value: $25, ROI: 7
- Ease of set up: 9
- Directions
- Advice: SHOULD DO
MIRRORS
Drop-in replacements for the inventory mirrors which have higher coatings and efficiency.
- Value: $33, ROI: 7
- Ease of set up: 9
- Directions
- Advice: SHOULD DO
CW 5200 WATER CHILLER
The CO2 laser tube is water cooled. Working it above its desired temperature (round 77°F/25°C) quickly degrades its efficiency and longevity. Routing the water by means of buckets of ice water is an inexpensive choice, however troublesome to take care of in sizzling climates for lengthy runs. I opted for a considerably outsized lively water cooler since my store will get near 100°F/38°C in the summertime. Watch out of cheaper thermolysis-type “coolers” that solely cross the water by means of a radiator with a fan, limiting the cooling capacity relying on ambient temperatures.
- Value: $450, ROI: 6
- Ease of set up: 8
- Advice: MUST DO (one thing for cooling); NICE TO DO (lively chiller)
DIY ROTARY AXIS
The K40 has a really restricted Z-axis area. Most industrial rotary axis instruments (that will let you engrave or reduce on cylindrical objects) won’t match inside and nonetheless preserve your workpiece at or under the required focal top. A 3D printed, low-profile rotary axis is a enjoyable venture and will be the very best use of area within the instrument.
- Value: $35, ROI: 6
- Ease of set up: 4
- Advice: NICE TO DO
HONEYCOMB BED
When the laser lastly punches by means of the fabric throughout chopping, it hits regardless of the materials was sitting on. If it’s a fabric that burns, then smoke or stains could accrue on the underside of the workpiece. Honeycomb is one method to handle elements of the issue by offering a deck that’s largely open below the workpiece. If the bottom below the honeycomb is closed, the smoke that collects within the cells can ignite and add oddly patterned char, so it’s not good for all supplies.
- Value: $18, ROI: 5
- Ease of set up: 7
- Advice: NICE TO DO
Z-AXIS TABLE
An adjustable-height desk that evenly raises and lowers the deck whereas retaining it degree is a giant enhancement. Thingiverse has a lot of fashions for each stepper-motor and manually pushed tables.
- Value: Varies, ROI: 8
- Ease of set up: 4
- Hyperlink to half: Search “K40 desk” (there are dozens) on Thingiverse or your favourite 3D repository. Add assorted nuts, bolts, shafts, and so on. as directed.
- Advice: NICE TO DO
GRAPHIC LCD
That is an exterior show and knob/button that gives the identical type of on-machine info and management that you just get on newer
3D printers.
- Value: $45, ROI: 4
- Ease of set up: 9
- Hyperlink to half: cohesion3d.com/store/peripherals/
graphic-lcd-control-panel-with-adapter - Directions: cohesion3d.com/knowledgebase/graphic-lcd-overview
- Advice: NICE TO DO
SUMMARY
I paid $454 for the OMTech K40, and $1,203 for the upgrades. Together with gross sales tax in Austin, Texas, my remaining price for this entire system was $1,794.
I was skeptical {that a} 40W laser cutter/engraver could be a sensible instrument. However regardless of its restricted workspace (12″×8″, or about 300mm×200mm) the vary of supplies it really works with mixed with the benefit of setup and use has made my K40 a go-to instrument, particularly for inventive initiatives, in my store. Plus, it was tons of enjoyable to mod and improve! 
