Using a laser cutter to make a speaker casing with style
When Chilean designer Francisco Sahli needed to take his tunes on the road, he decided the best way would be to make his own stylish bluetooth speaker.
Many makers turn to laser cutting to build enclosures for their electronic projects. What sets this example apart is the departure from the usual boxy laser cut forms, with the result looking much more like a manufactured product.
Rather than the usual slotted laser cut corners, Francisco achieved a smooth radius and angled faces by laser cutting timber profiles and then laminating them together.
The final assembly was then carefully sanded by hand, before three coats of paint were applied. You can read all about the construction process, see the laser cutting paths and find out what’s inside to make the bluetooth speaker work its magic on Francisco’s website.
Taking a step back to go through some laser cutter basics.
What is laser cutting, and why are we so excited about it?
As we’ll see in this brief overview, laser cutting is a relatively simple technology that makes it possible to cut or etch forms from sheet materials.
Laser cutters work in a similar way to other CNC (computer controlled) tools, however the cutting is done with a powerful beam of light instead of a sharp blade. To cut, the laser beam is focused to hit the material at a precise point, causing it to melt, burn or vaporize. Etching is achieved by focusing the laser on the surface of the material, where it will only burn or vaporize the topmost layer.
Laser Cutting is particularly useful because it works touch-free, meaning no mechanical forces or pressures are transferred to the material. This enables delicate cutting paths that can be repeated with a high level of precision, whether they are cut all the way through the material or etched as an impression onto the surface. (more…)
Left to right: 3.5mm Maple, Cherry & Walnut Veneer
We’ve expanded our material selection in the US with three new premium wood veneers.
These high quality veneers have a wood laminate on each side which is sanded smooth and finished with a clear coat. The premium appearance makes these materials ideal for jewelry, coasters, clocks, or other high end products.
Click on the images below or head over to the materials page to get all the details on our new premium woods.
Leaves, MC Escher’s Rippled Surface and some sci-fi just for fun
Using a laser cutter to add physical presence to 2D artworks can be really effective, as these recent explorations from Maxime Beauchemin show. Having kicked things off with a rather elegant laser etched ATAT walker, he then moved on to more everyday ephemeral visions.
Pictured above is an acrylic replication of MC Escher’s iconic Rippled Surface print, where Maxime faithfully recreates the layered illusion of water surface, reflected trees and rippled distortion.
Turning to laser cut wood for another project, the delicate structure of a decaying leaf skeleton is revealed. (more…)
Space saving portable design takes laser cutting on the road
Here is another interesting DIY laser cutter project, this time featuring a novel departure from the standard construction we are used to seeing.
Instead of running within a constrained space, the compact laser cutter has an arm that swings out in a format reminiscent of the RepRap 3D printer.
When the laser cutter is in use the arm opens up to 90 degrees perpendicular to the box and the laser head runs along it.
The main structural elements are made from aluminium extrusions, and there are a few custom CNC milled and 3D printed components to fill in the gaps and connect other off-the-shelf parts.
This looks to be a novel way to build a laser cutter that you can take on the road with you. No more heavy equipment fixed in place in the workshop… just be careful not to set it up on your grandma’s favourite coffee table!
For more info, including a thorough photo essay of the development process behind the fold-out laser cutter, click through to the source.
Running interesting laser cutter experiments is one of the things that Just Add Sharks does best. In this exploration, they have addressed the question of how to break away from the mortice and tenon joints that have become so familiar in laser cut projects.
By creating a laser cut jig that holds the material at a specific angle, they were able to cut edges that can fit together in a manner that is clean and precise. No more stepped blocks and slots! Here is what the jig looks like:
Much easier to achieve than modifying the axis of the laser cutter itself, this jig provides a firm support to a pre-cut panel, and does not require any other machine modifications. The angle of the cut can be controlled by altering the vertical supports.
“Manually changing the angles like this is tiresome so the next sensible upgrade would be to build an ‘any angle, any material thickness’ jig for the same purpose, but that is a job for another day.”
The Just Add Sharks blog has an overview by Martin Raynsford that talks through a few of the considerations that led to the first successful cut. Having proven that it can be done with standard perpendicular joints, they adjusted a few specs on the jig to produce a icosahedron, pictured below.