LaserCAMM

A rapid prototyping manufacturing process involving the user of a low-power laser beam which works like a plotter.

	Overview
How it works Suitable Materials Applications		Size & Shape Limitations Cost & Speed Technical details
	Conclusion Links

Overview

LaserCAMM is a turn-key laser cutter that integrates with many CAD systems. By combining the power of laser cutting with the flexibilityof CAD, LaserCAMM turns complicated drawings into laser cut parts. Similar to a pen plotter, the system uses a laser beam to cut and scribe a variety of sheet materials into intricate patterns. Here are the distinctive features of LaserCAMM that facilitates rapid prototyping:

Best suited for 2-D objects
Can be combined to create 3-D models
Efficient system - data is sent electronically to the laser
Speedy manufacture process
Overcomes size and material limitations

How It Works

But how does LaserCAMM work?

The LaserCAMM machine is similar in size and appearance to a large office copier and fits in an office or workshop environment. In operation, a sheet of material is placed on the LaserCAMM’s 2’x 4’ vacuum bed, the cover is lowered, and the sheet is then scored, perfed or cut according to a CAD-generated DXF file. Pulsed CO2 lasers, ranging in power from 50 to 150 watts, are used to cut and score a wide range of materials up to 1" thick.

Summary of procedure:

Import PC CAD File to Machine
.dfx file format
Position Material In the Machine
CO2 Laser moves Like a Plotter
Laser diameter depends on model specs
Cuts and Etches Two-Dimensionally at 5 levels
Can Be Assembled into 3-D Models
Solid section
Cross section, or “Egg crate” (see right)

Sample

Suitable Materials

Acrylic up to 1” thick (see right)
Plastics
Fabric
Rubber

Wood (see right)
Cardboard
Foam
Composites

Applications

Here are some of the possible uses for LaserCAMM:

Architectural models
Prototypes for engineering
Industrial designing and manufacturing
Entertainment special effects model and photo props
Signage and custom logos

Exhibits and trade show displays
Stencil cutting
Novelty, gift production
Package designs
Etching/scribing

Size and Shape Limitations

Maximum cutting area: 35”x21” to 52”x26”
Maximum cutting thickness: 0.25”-1.0”
Maximum cutting speed: 200 in./min
Accuracy: 0.005 in./ft

Technical details

On order to handle designs of different dimensions and complexities, many models of LaserCAMM machines with various ratings have been designed. The following tables show the different models available at this time.

Model 2305:

Physical:	57"( 145 cm) x 34" (86 cm) x 44" (111 cm)
Laser:	Coherent G-50 50 Watt
Electrical:	1Phase, 220 V AC, 60 Hz, 15A
Cutting Area:	36"( 91.4 cm) x 21" (53.3 cm)
Maximum Cutting Speed:	200(+)" (508 cm) per minute
Interface:	Windows 95/98/NT based LaserCAMM Software, DMC generated form DXF file cutting format
Saftey:	Interlocks on all doors and cover, ON/OFF keylock
Classification:	Radiation preformance standards 21 CFR subchapter J, Class 1 Laser System

Model 2310:

Physical:	57"( 145 cm) x 34" (86 cm) x 44" (111 cm)
Laser:	Coherent G-100 100 Watts
Electrical:	1 Phase, 220 V AC, 60 Hz, 25A Chiller: 1 Phase, 220 V AC, 60 Hz, 20A
Cutting Area:	36"( 91.4 cm) x 21" (53.3 cm)
Maximum Cutting Speed:	200(+)" (508 cm) per minute
Interface:	Windows 95/98/NT based LaserCAMM Software, DMC generated form DXF file cutting format
Saftey:	Interlocks on all doors and cover, ON/OFF keylock
Classification:	Radiation preformance standards 21 CFR subchapter J, Class 1 Laser System

Model 2405:

Physical:	74"( 188 cm) x 41" (104 cm) x 44" (111 cm)
Laser:	Coherent G-50 50 Watt
Electrical:	1 Phase, 220 V AC, 60 Hz, 15A
Cutting Area:	52" ( 132 cm) x 25" (63.5 cm)
Maximum Cutting Speed:	200(+)" (508 cm) per minute
Interface:	Windows 95/98/NT based LaserCAMM Software, DMC generated form DXF file cutting format
Saftey:	Interlocks on all doors and cover, ON/OFF keylock
Classification:	Radiation preformance standards 21 CFR subchapter J, Class 1 Laser System

Model 2410:

Physical	74"( 188 cm) x 41" (104 cm) x 44" (111 cm)
Laser	Coherent G-100 100 Watts
Electrical	1 Phase, 220 Vac, 60 Hz, 25A Chiller: 1 Phase, 220 Vac, 60 Hz, 20A
Cutting Area	52" ( 132 cm) x 25" (63.5 cm)
Maximum Cutting Speed	200(+)" (508 cm) per minute
Interface	Windows 95/98/NT based LaserCAMM Software, DMC generated form DXF file cutting format
Saftey	Interlocks on all doors and cover, ON/OFF keylock
Classification	Radiation preformance standards 21 CFR subchapter J, Class 1 Laser System

Model 2415:

Physical	74"( 188 cm) x 41" (104 cm) x 44" (111 cm)
Laser	Coherent Diamond 64 150 Watt
Electrical	3 phase, 220 Vac, 60 Hz, 42A Chiller:
Cutting Area	52" ( 132 cm) x 25" (63.5 cm)
Maximum Cutting Speed	200(+)" (508 cm) per minute
Interface	Windows 95/98/NT based LaserCAMM Software, DMC generated form DXF file cutting format
Saftey	Interlocks on all doors and cover, ON/OFF keylock
Classification	Radiation preformance standards 21 CFR subchapter J, Class 1 Laser System

Cost and Speed

Generally, the main advantages of LaserCAMM are that it is user-friendly and cost-efficient. The software interface is straight forward -- A DXF file generated from a CAD program is imported into a Windows 95-based user software and converted to a DMC file that is read by the LaserCAMM machine. The conversion entails selecting predefined functions, such as cut or score (depth 1 through 5) to given layers. There is also the capability of customizing settings for unique materials or requirements. Previewing the cut path prior to sending is available, as well as the ability to estimate the cut time and material required. Once the file is downloaded, the material is put in place and the focus set. Then the laser is switched on and the material gets cut according to specifications. Only minimal training is required to carry out the entire process.

Summary of pros and cons:

Pros	Cons
Low cost - $10-$15 for 75 4"X6" index card-sized pieces Labor, shipping Material Fast, 80% faster than other rapid prototyping processes 2-3 days(after receipt of .dfx file) Material diversity Compact machine, with mininal training requirements Precise cutting	Expensive investment - equipment, software 2-D cut only Requires very specific parameter details Does not cut metal or paper

Conclusion

LaserCAMM is a process best suited for manufacturing 2-D designs because of the way the procedure works. Materials used should be relatively thin, and have a low flash point. LaserCAMM should be used for parts which are transparent or made of acrylic, for such designs will pose more difficulties for the other rapid protyping processes.

In short, LaserCAMM is:

A fast, accurate, cost-effective process
Best-suited for 2-D models
Done using computers and CAD software
Able to handle a wide range of materials
Able to handle objects of many shapes and sizes

Links

Melissa Chan	mlc@andrew.cmu.edu
Vaughn Coolman	coolman@andrew.cmu.edu
Harn Hua Ng	hng@andrew.cmu.edu

8 Mar 2000