Design and Testing of Components for a Low Cost Laser

The main goal of this thesis is to document the design and testing of various components for use in a low cost laser cutting mechanism for hobbyists and recreational designers. Different electronics were used to assess the cutting potential of a laser diode, a small silicon chip based laser light producing unit. A test rig was constructed to evaluate the cutting potential of the laser diode, and several tests were conducted on different materials. In addition, a low cost positioning machine design was also explored, which used servo motor actuators to drive the system and was used to evaluate the potential of using a potentiometer for position feedback. Tests with the laser diode using different cutting strategies revealed that the cutting potential of the diode is limited and not likely well suited for cutting through materials of useful structural thickness (0.125 inch to 0.25 inch thick materials). The tests of the potentiometer feedback were positive, indicating that potentiometer feedback is a good method for low cost position control. However, the mechanical designs tested proved insufficient for positioning the system to within 0.01 inches of the commanded coordinates so further improvement is necessary. Thesis Supervisor: Daniel D. Frey Title: Associate Professor of Mechanical Engineering and Engineering Systems Acknowledgements I would like to thank my parents for always supporting me and letting me find my own path through life. I would also like to thanks Carmen Graves, and all of my other friends who had to deal with the constant smell of burnt plastic. A special thanks to Professor Frey, who allowed me to explore a project in which I had personal interest, and guided me along the way.