CTL-ENGINEERING

ENRICHMENT WINTER 2022

LASER CUTTING AND 3D By: Osama Desouky
December 27, 2022
SCANNING FOR ENGINEERING
PROJECTS
 ABOUT ME
 Teaching technical laboratory coordinator,
Mechanical Engineering 2019
 Research Assistant 2016- 2019
 Bachelor of Science, Mechanical Engineering 2016
 Team Manager for Shell eco marathon 2016
 Master of Science, Chemical Engineering, 2022
 Interests: 3D printing, Materials science, Fabrication
and DIY projects, Car Maintenance, design, and
teaching
Office: 228B
Phone: 4423-0235
 ABOUT THIS COURSE
 The course is an introductory level into
new prototyping technologies needed for
campus wide students in fabricating their Time Activity
own simple structures. 9:00 am -9:15 am Welcome and
introduction
(1) Laser cutting as a precise and quick solution 9:15 am – 10:15 am Laser cutting and
limitations
for various academic courses and for hobbiests 10:15 am – 10:30 am Quick break
who enjoy building their structures. 10:30 am – 12:00 pm Practice with laser
cutting and engraving
12:00 pm – 1:00 pm Lunch break
(2) 3D scanning is emerging and is needed by 1:00 pm – 2:00 pm 3D scanning tools and
many students in scanning objects they would like methods
2:00 pm – 3:30 pm Practice on 3D
to integrate into their senior design, laser scanning scanning
allows achieving accurate and detailed designs
without the need for detailed CAD modeling
techniques

 What to expect?
 Theory
 Hands-on Experience
LASER CUTTING
PRINCIPLES
 NAME THE FOLLOWING
MANUFACTURING
TECHNIQUES?

Laser cutting/Engraving CNC-subtractive Manufacturing 3D printing

MANUFACTURING
PRINCIPLES
1. Subtractive: material removed from a solid block until you reach the desired form
2. Fabricative: elements or physical material are combined and joined
3. Formative: mechanical forces and/or heat are applied to a material to form it into
the required shape; e.g. bending, casting and moulding
4. Additive: Material is manipulated so that successive pieces of it combine to make
the desired object
LASER CUTTING PRINCIPLES
 Which category is Laser cutting?
2D or 3D?
Laser cutting is a type of thermal separation
process
The laser beam hits the surface of the material
and heats it so strongly that it melts or completely
vaporizes
The laser system follows the selected geometry
and separates the material
LASER BEAM
CHARACTERISTICS
OVERVIEW OF LASER
CUTTING
 Optical fibre lasers were first demonstrated in
1961 by Elias Snitzer
The gas laser cutting process, using a carbon
dioxide mix, was first invented in 1964 at Bell
Labs, by Kumar Patel
The crystal laser process for cutting was
developed, also founded at Bell Labs in 1964, by
a different engineer named J. E. Geusic.
The laser was intended for military applications
Cuts were made using oxygen assist gas in high
carbon tool steel and stainless steel up to 2.5mm
thick at speeds up to 1m/min
APPLICATIONS
 Electronics
 Medicine
 Defense
 Automotive
 Design
 Education
 DIY
 Can you think of application of Laser
cutting you use everyday?
 DIFFERENT
METHODS/TECHNOLOGIES
 CO2 Laser Cutters
 Consist of CO2 gas along with a mixture of other gases like helium and
nitrogen. This type of gas mixture is charged up by electric discharge which
then produces the laser beam. The wavelength of such cutters is 10.6mm.
 Materials: Glass, plastics, leather, wood, and acrylic.

Crystal Laser Cutters

 Generate beams from Neodymium doped yttrium ortho vanadate
 The wavelengths of these cutters are smaller as compared to CO2 laser
cutters hence they can cut through some thicker materials.
 Smaller wavelength also contributes to better focus and higher intensity
 Materials: Plastics, Metals, and Ceramics.

 Fiber Laser Cutters

 Cutting of reflective and conductive metals, thrice the times of efficiency as
compared to CO2 laser cutters, and the absence of movable parts
 Fiber lasers can work on metals as well as organic materials.
 Efficient and low maintenance.
 Materials: Metals and Organic materials.
DIFFERENT LASER TYPES
PROS-CONS
 A wide variety of metallic and  High equipment cost.
nonmetallic materials can be machined.
 Unsafe operation for eye.
No mechanical contact, and no
deformations of workpiece and no tool  Blind holes of precise depth are
wear are encountered. difficult to achieve.

It produces micro features in difficult-  Laser produces tapered holes.

to-machine and refractory materials.  Sharp corners are difficult to produce
It is easy to control the beam  HAZ cannot be avoided.
characteristics to adapt to a specific
machining duty.  Unpolished surfaces are preferred
Machining speed is high.
LASER BEAM MACHINING
 LBM is used to cut and machine both hard
and soft materials, irrespective of its physical
and mechanical properties.

To make the laser beam useful for machining,

its power density should be increased by
focusing, thus attaining power density values
between and .

Machining of Al, Cu, Ag, and Au is being

especially problematic, as these metals are of
high thermal conductivityand have the
tendency to reflect the light.
MODES OF OPERATION
• Continuous wave (CW) and pulsed (P)
modes
•Generally, CW lasers are used for
processes like welding, soldering, and
surface hardening that require an
uninterrupted supply of energy for
melting and phase transformation.
•Controlled pulse energy is desirable for
cutting, drilling, marking, and so on,
striving for less heat distortion and the
minimum possible HAZ.
PEAK LASER POWER
 Average Power ()
 Pulse frequency (f)
 Pulse Duration ()

CO2laser is an infrared (IR) laser beam of long wavelength

(λ = 10,600 nm) and with low photon power
HOW TO MAKE MY OWN
PART?
WORKING PRINCIPLE
EQUIPMENT FUNCTIONS
 Lasing material: (solid state or gas)
 Pumping energy source: required to
excite the atoms of the lasing material to
a higher energy level
Mirror system: One of these mirrors is
fully reflective, while the other one is
partially transparent to provide the laser
output (output mirror). It allows the
radiant beam to either pass through, or
bounce back and forth repeatedly
through the lasing material
HOW IT WORKS?
 Material absorb laser energy to be
heated and melting
When power density and , evaporation
of material on surface will become high
density plasma, resulting in reducing
absorption of laser. This effect is called
as plasma shielding effect
MATERIAL REMOVAL RATE
PARAMETERS
 Speed
 Power
 Material dependent
 Thickness
CHECK LIST
Check your cutter
Check your dimensions
Check the power of cutter
Select the correct material
LETS START MAKING THINGS!

Dimensions: 615 x 445 x 177 mm

Weight: 22 kg
300 x 210 x 45 mm ( 11.81" x 8,27" x 1.77"
Work Area:
inch )
Camera Preview Area: 300 x 195 mm
Voltage: AC 110V / 220V
Touch Panel: 1024 x 600 LCD
Camera: HD CMOS
I / O: Wi-Fi / Ethernet
Laser Spec: 30W CO₂ Laser
Laser Wavelength: -
Laser Moving Speed: 0 ~ 300 mm/s
Laser Cutting Thickness: 0 - 5 mm (varies by material)
Software Mode: Vector / Graphic (monochrome, gray scale)
Software Operating System: Windows / macOS / Linux
Software File Type: JPG / PNG / SVG / DXF
BEAM STUDIO
LET US PRACTICE
Task 1: Coasters Task 2: Water Bottle
3D SCANNING
WHY
3D scanners?
Reverse Engineering
PROCESS?
3D SCANNING
 Efficiently takes the measurements of
contoured surfaces and complex
geometries
 Requiring vast amounts of data for
accurate description
 3D scanning technologies vary with
different physical principles
TYPES
 Laser triangulation 3D scanning  Structured light 3D scanning
technology: In this category, the laser technology: This technology involves
scanner projects a laser beam on a projecting structured patterns of light on
surface and measures the deformation of an object and acquiring a surface's shape
the laser ray. by measuring the light pattern's
deformation.
TYPES
 Photogrammetric technology: It is  Laser pulse 3D scanning
also known as a 3D scan from technology: This unique process
photography. It reconstructs an object collects geometrical information by
from 2D to 3D and has specific evaluating the time a laser beam takes to
computational geometrical algorithms travel between its emission and
for the task. Photogrammetry is cheap, reception.
precise, and used to scan large objects
such as buildings and stadiums.
 TYPES
Computerized Tomography (CT
scan): A widely used technique in the
medical sector, CT scan is generally
used to scan images of the human
interiors. CT scans consist of scanning a
part and taking a series of 2D images of
various sections with X-rays. The 2D
images are later superimposed on each
other to imitate a 3D model
SCANNERS AND TYPES
 Short Range 3D scanners: Short Range 3D scanners  Structured light 3D scanners: These are also
utilize either a Laser triangulation technology or known as white light scanners. However, most
Structured Light technology structured scanners use blue or white LED
 Laser-based 3D scanners: These scanners employ lights. The light pattern usually consists of a
trigonometric triangulation to capture a 3D object as geometrical shape such as a bar, block, or other
millions of points. Laser scanners work by projecting a shape projected onto the object. The sensors
laser beam or multiple laser beams on an object and
capturing its reflection with sensors located at a fixed consider the edge of the pattern to determine
distance from the scanners. Laser scanners come in the 3D shape of the object. Blue or white light
various designs such as handheld portable units, arm- scanners are generally used to obtain outward
based, CMM-based, long-range, and single-point long- dimensions. Medium and Long range scanners:
range trackers. Long-range 3D scanners are used for large
 Arm-based scanners: Arm-based scanners are handy objects such as buildings, ships, aircraft, and
when measuring small minor parts, as they can be military vehicles. These scanners rotate and
maneuvered by attaching them to the arm and is spin a mirror which reflects the laser outward
generally portable. towards the thing or areas to be 3D scanned.
EXAMPLES
SOFTWARE FOR PROCESSING
EXSCAN- Fusion 360
TEXTURED VS NON-
TEXTURED
MESH MODEL
MESHED MODEL
FUSION 360
 STL Repair
 Healing
 Surfaces
 Merge Surfaces
 Add Surfaces
 Save as obj. or STL
Click icon to add picture

THANK YOU December 27, 2022