LaserCAMM
LASER Computer Aided Modeling and Manufacture

What is LaserCamm?
LaserCAMM is essentially a turn-key laser cutter that integrates fully with many CAD systems. The basic mechanism of the system works similar to a pen plotter. The system uses a laser beam to cut and scribe a variety of sheet materials into intricate patterns. Any shape that is drawn on your CAD system can be precisely cut by LaserCAMM. LaserCamm is so versatile that it has the ability to handle splines and ellipses. It is also very useful because it provides immediate feedback on complicated parts that can help resolve manufacturing problems

How does it work?
A Laserbeam is directed through a set of mirrors that move on the X-Y axis to create the desired pattern on the horizontal place. The pulsed laser is of CO2 ranging in power of 50 - 150 Watts. An air jet blows material out and away from the beam after it is cut and a vacuum holds the parts against the honeycomb bed during the cutting operations and helps remove fumes.

3D Model Applications
Although LaserCAMM is a two-dimensional process, it can be used to create 3D models for a variety of purposes.
There are two methods for creating models from flat pieces:

Standard stacking involves sandwiching and adhering together parallel slices of a 3D object. The result can be worked by hand to a finished model.

Cross-sectional prototyping is a process by which LaserCAMM's software divides a 3D CAD model into perpendicular slices, which form a 3D approximation of the form when fitted together. The software calculates the slices' shapes and locations within the 3D form, and includes holes to insert rods for assembly. The result resembles an egg crate, with open cells between the perpendicular slices. T he spaces can be filled with foam, for a finished form.

• product design process models
• automotive exterior & interior
• aerospace & wind tunnel scale models
• large scale part tooling
• exhibit models
• film special effects, 3D props
• architectural models

Design Information Interface
A DXF file generated from a CAD program is imported into the Windows 95-based user software and converted to a DMC file that is read by the machine. Software interface is that straight forward. You can also customize 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. LaserCAMM is so user-friendly that only minimal training is required. A designer doesn’t have to rely on trained technicians to create parts.

Materials that can be used
The LaserCamm system can be used to cut and score a wide variety of materials from plastics, to metal, to paper products. Depending on the design some materials may be unacceptable because of dangers of scorching or fire as a result of the heat of the laser beam. Plastics should also be selected for high melting points because otherwise the material may curl up and deform at the edge cut by the laser beam.

Plastic Sheet Stock acrylic (up to 1" thick) styrene delrin nylon teflon polypropylene polycarbonate foam (up to 2" thick) metalized plastics plastic laminate

Other Materials wood fiberglass plywood veneer masonite fiberboard anodized aluminum(scribing) rubber composites fabric cardboard

For the purposes of this assignment the material is constrained to Plexiglass to make specification easier for Stanford University.

Shape and Size Limitations
The size of the material is constrained by the size of the machine bed which ranges from 21"x36" to 26"x 52" depending on the model specification of the Lasercamm. The thickness allowed with the Lasercamm process is dependant on the material itself and in the application. Nevertheless, thicknesses larger than 1'' are not recommended (Stanford will only process thickness up to 1/2'').
As mentioned before, only 2D cuts can be made, but 3D models can be achieved as described above.
The thickness of the laser beam is between 0.010'' and 0.020'' which must be accounted for during the design process.

Cost and Time
Manufacturing cost of a LaserCamm really depends on the size and the materials that it is being used. But relatively speaking, it is a very cheap rapid prototyping method. For example, to create our spur gear it will cost roughly $3 for the material. Cutting cost will depend by the company used but it will not be expensive. Initial cost for buying a Lasecamm machine itself can range from $90,000 to $120,000 depending on the model.

Turn around time for the Lasercamm process is also very fast. Products can be created in minutes. Most Lasercamm can cut up to 200'' per minutes. We expect our part's turn-around time to be just a few days.

How to make your own LaserCamm Part

1. Create a Cad of your design
2. Convert the Cad File into a DXF 14.
3. Send the DXF file via internet to a LaserCamm operator(school or business)
4. Wait for finished product to arrive