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Machine tools are dangerous and may cause great injury.  This information was collected from a variety of sources, is neither complete nor verified, and is of a general nature for theoretical study only.  Any attempt to duplicate the operations described should be done with the guidance and supervision of a qualified instructor who will teach the appropriate safety skills and fill in the missing details.  Follow this link for Statements of Warning, Limitation & Responsibility.

Advanced Manufacturing Processes - El Camino MTT 107
Intro Laser-Machine Projects

StudioScanHD Laser Capture
Epilog Laser Engraver

Advanced Manufacturing Processes: Course Description
This course covers the principles and operation of machine tools with an emphasis on advanced manufacturing processes and machines, such as EDM (Electrical Discharge Machines), water abrasive jet machines, and grinding machines. Additional topics will include abrasives, coordinate measuring machines, advanced precision measurement, GD&T (Geometric Dimensioning and Tolerancing), optical comparators, and practices and setups as applied in industry. 

StudioScanHD Laser Capture
 After booting up StudioScanHD, Click on SCAN.
Keep the laser away from your eyes!!
1. Begin StudioScanHD from the computer's opening Desk-top page.

2. StudioScanHD will boot up, and a screen shown here will appear. 

3. Click SCAN.  A picture and scan-options will come up on the screen.
Set your Scan distance to Macro or Wide, depending on how far away your object is.4. Place an object in front of the Laser Scanner and adjust it so it shows on the screen.

5. Dark and Dull things scan best.

6. Choose Wide or Macro Distance... Depending upon how close your object is to the laser. 

7. If you want, you can "Click & Drag" a box for the area to be scanned.  This will reduce trimming later. 		First make several "Single" scans to test different settings. Then switch to the "360" 3D scan.
You can also raise the scan platform during placement. In "Macro" mode you want the part about 6 1/2 inches from the laser.8. I think the ideal setting for Macro is six and 1/2 inches away from the laser.
This gear was too shiny to scan well. It would also have helped to put some distinctive marks (letters or numbers) on the part for assembling the 3D scans.		 Take a few single-scans with different settings to see what works best.
9. Make your setting selections.

10. When scanning this cup I used the "Quick" Speed, a relatively Light "Surface Setting",  "Mate", The Second Level "Triangle Size".  I found that it is best not to use too much "Smoothing".

11. Make a few "Single" scans with different settings and compare to see what comes out best.
When "360" scan is complete, choose "Align" to bring the pictures together.15. Two scans of your object will appear, each with a Red, Yellow, and Blue Dot.  With each scan, place the Red and Yellow dots at the same places on the two different pictures.

16. "Attach" the scans.
 Once you have done the 360 3D scans, it is time to align the pictures.12. When you are getting a good scan, delete the "Single" scans shown in green at the bottom of your screen.  Now you can do a "360" scan.

13. Choosing more "Divisions" will scan more accuracy, but take longer.  Eight "Divisions" (separate pictures) worked well when scanning this cup.

14.  As your object scans, you will see separate pictures piling up on each other.  When it is finished with all scans, click "Manually Align.
A close-up of placing Red & Yellow dots. Two dots placed on each scan should be enough to "Align". Here is the assembled cup... patched together from the 3D scans.
17. This might be a good time to "SAVE" your scans.

18. Select the "Scissors" icon.

19. Some trim options will come up on the screen.  Use these shapes to highlight in RED the areas you would like to trim.

20. Click "Scissors" icon again to trim away red selections.
StudioScanHD puts together a virtual part with thousands of data-points. 21. StudioScanHD has different view options.  This one shows a "Map" of the different coordinate data points collected by the laser.  The StudioScanHD is capable of accuracy within 0.005.

22. The laser scan file may be saved and imported into SolidWorks or Inventor.  From there you can take it into MasterCam, and use it to program tool paths that will machine your part.
A car model scanned and aligned. Data points ready to be loaded into MasterCam for machining.
23. A model car was scanned on the StudioScanHD. 

24.  The coordinate points (shown at Right) were loaded into MasterCAM and scaled up so that a larger model could be produced in foam on a CNC router.

Epilog Laser Engraver

 The Epilog Laser Engraver. Remember to plug in the ventilator!!
 Create a "New" file and import your picture. I increased the contrast levels on the picture of this South Bend lathe and saved it as a PNG file.1. The Epilog Laser Engraver basically works like a printer that shoots a laser instead of ink.

2. The way we make it work is to create a CoralDraw file, and then print it to the laser.

3. Find out what kinds of CoralDraw files you can use(.DXF .WG) open one you want to "laser-print".
4. You may have trouble getting CoralDraw to open files.  One solution: create a .PNG file and save it on a USB stick.

5. Open up a "New" CoralDraw file, and "Import" your .PNG file.

6. Turn on/plug-in the ventilation..  laser-engravers create smoke.  Some materials give off fumes.  		Lean the lid all the way back so it doesn't fall.
7. When opening the Epilog Laser Engraver, make sure to lean the glass top all the way back.

8. PVC and Vinyl create fumes that are Bad for the Engraver and you!!!  Check with the instructor to make sure your materials are acceptable.
Here's a picture of the Depth-Guage used in focusing the laser. 9. Put your material to-be-engraved in the Epilog Engraver.

10. Set the focal length of the laser by placing the Focus-Bracket/Depth-Gauge in place next to the laser. 

Push the "Focus" button. Jog the Depth-Gauge up/down until it touches your material. Press the "Reset" button.
11. Hit the "Focus" button on the front of the Epilog Engraver.

12. Jog the Depth-Gauge using the Up-Down Arrows until it touches your material.  Hit the "Reset" button.
13. Remove the Depth-Gauge from the laser and close the top of the Epilog.

14. Go back into CoralDraw and "Print" your image. 

15. Push the "Go" button.

16. The laser will begin moving back-and-forth.		 You can't tell from the picture, but the laser is moving back-and-forth pretty quickly right now.



17. The image you "Printed" from CoralDraw will be burnt into your material.

18. Remember to shut off the Engraver, unplug ventilation, and give the Depth-Gauge back to the tool room.


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