Summary

The Open Source ZelosLaser Cutter V2 is a full working unit to engrave and even cut material like plastics, wood, leather and much more. It is easy to build and has a number of exclusive features that cannot be found on other engraver machines.

If you build one, please share a picture! :)

Lets Engrave : ZelosDynamics Logo on Plywood
https://www.youtube.com/watch?v=hhykOXjyOjY

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Instructions

ZelosLaser is the world’s first, high stable and completely open-source laser cutter and engraver. It has been designed to be sturdy, affordable and versatile. As open-source technology, we are also offering a number of documentation online for its design and implementation. Easy to build in under 4-5 Hours!

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BOM - bill of materials

Qty Part Name
5x Aluminium profile 20x20 Type B 15cm
4x Aluminium profile 20x20 Type B 30cm
4x Aluminium profile 20x20 Type B 40cm
8x Screws M2.5x15 (Wood version
13x -M3 Allen SCREW M3x10
6x -M3 Allen SCREW M3x16
12x -M3 Allen SCREW M3x20
5x -M3 Allen SCREW M3x25
89x -M4 Allen SCREW M4x8
14x -M4 Allen SCREW M4x20
89x washers M4 wide Brim
24x nuts M3 Normal
8x M3 lock nut
20x M4 Normal Nut
96x M4 threaded plate M4

1x GT2 Timing Belt 57CM
2x GT2 Timing Belt 87CM
2x GT2 Timing Belt 158mm Closed Loop
3x Timing Pulley GT2 20 teeth, 5mm Bore
4x Timing Pulley GT2 20 teeth, 8mm Bore
1x Steel Rod 8mm diameter 29,5cm
2x Steel Rod 8mm diameter 29CM
2x Steel Rod 8mm diameter 42CM
6x LM8UU linear bearings
3x 608z bearings
1x MDF Wood Base Plate 28x32 / 7mm thin
1x Laser protective glasses
3x Nema 17 stepper motor 36oz
1x Arduino Uno R3 or clone
1x GRBL-Shield
2x Pololu a4988 Stepper Driver
1x Power Supply 12V / 4A
2x 12V fan 4x4cm
2x Power Switch
1x Laser protective glasses
1x Laser Module 445nm 2watt M140 diode Copper Modules With Leads & Three Element Glass Lens
1x Laser Driver 3A 450nm TTL
4x Endstops
2x handholds
1x Various cable, different plugs ...
1x 3D PRINTED PARTS

Tools you need
Allen Key M4
plier screwdriver
screwdriver
a brush or something similar
Metalsaw when the steel rods or aluminum profiles are not even cut when you buy it.
Jigsaw when the base plate has not been cut when buying

some wood glue (to glue a thin layer of cork on the bottom plate)

BUILD IT
Begin with the aluminum profiles. screwed all together like in the Images.
Do not forget to push enogh M4 threaded plates into the V-slot of the profile.

Baseplate
glue the cork to the bottom plate as in the photos.
use a brush or similar to remove all the small blisters.

Turn around the bottom plate and put some weight on it.

Wait until the glue is dry.

Attach the handholds and Baseplate to the Frame
Attach the handholds with 4x - M4x20 screws.
Attach the Base Plate with the printed Holders.

Prepare the axis
Sliding/push the LM8UU linear bearings on the Steel Rods.
Attach the steel rods to the chassis.
fix the carriage to the linear bearings with cable ties.

Electronics/wiring

Wiring Diagram for 2watt Laser
For the wiring we use a very reinforced system.
it is very easy to build and works great.

-If you want to use two motors with two Stepper Driver for Y axis, you can "clone" any axis for use two motors and two drivers for a single axis. The CNC shield is capable of it
Check this for more CNC shield infos.
http://blog.protoneer.co.nz/arduino-cnc-shield-v3-00-assembly-guide/

Don´t connect the laser before adjust the power on the laser driver.

SOFTWARE
Before you can start you need the Arduino IDE, available on their webpage.
Arduino IDE http://www.arduino.cc/en/main/Software

Modified firmware for the Arduino UNO R3 or similar clone:
http://www66.zippyshare.com/v/2N7UjyV3/file.html
GRBL0.9i_Library_zelosLaserengraverV2.zip

(Modified for Version 2.0 ZelosLaser Cutter with 2 Axis)

Grbl wiki: github.com/grbl/grbl/wiki

drawing software: Inkscape 0.91/combined with a laser engraver plug-in.
https://inkscape.org/de/
( we use @now the one Plugin from the Microsclice Engraver. We are working on our own plugin)

Grbl needs G-Code.
http://reprap.org/wiki/G-code

We need another Program to send the G-Code to the Arduino UNO R3 board.

Grbl Controller 3.0 by Zapmaker http://zapmaker.org/projects/grbl-controller-3-0/

#############################################

NOTE: Before starting, make sure that any older installation of Grbl has been completely removed from the Arduino IDE.

Download the Modified Grbl source code (v0.9i)

Once downloaded, unzip it and you'll have a folder called grbl-master or something similar.

Make sure you are using the most recent version of the Arduino IDE (last tested on v1.61).

Load Grbl into the Arduino IDE as a Library.

Launch the Arduino IDE.  Click the Sketch drop-down menu, navigate to Include Library, and click Add .ZIP Library, note that this still works with a folder (prior to IDE version 1.6.2 this will be Import Library..., and click Add Library...).  Select the Grbl folder inside the grbl-master folder when asked to select a library folder you'd like to add. The correct folder only contains the source files and an example directory.It may take a few seconds for the Arduino IDE to import it.

NOTE: For pre-v1.05 Arduino IDE users, you will need to manually add Grbl into your Arduino libraries, so that it will appear in the Import Library... menu. Search the internet for how to install, then skip to step 4.

Open the GrblUpload Arduino example.  Click the File down-down menu, navigate to Examples->Grbl, and select GrblUpload.  Compile and upload Grbl to your Arduino.  Connect your Arduino Uno to your computer.  Make sure your board is set to the Arduino Uno in the Tool->Board menu and the serial port is selected correctly in Tool->Serial Port.  Click the Upload, and Grbl should compile and flash to your Arduino! (Flashing with a programmer also works by using the Upload Using Programmer menu command.)

Once you have your Grbl library set up in the Arduino IDE, you can update, replace, or modify the Grbl source code in the library folder. On a Mac, it's located in ~/Documents/Arduino/libraries/. On Windows, it's in My Documents\Arduino\libraries.

You may need to restart the Arduino IDE for this change to take effect.

No fuss! No muss!

https://github.com/grbl/grbl/wiki/Compiling-Grbl

I hope you guys like the tutorial.
many greetings,
Zelos-Dynamics

ZelosLaser Cutter 2.0 : Open Source, Sturdy & Versatile