DEVELOPMENT AND TESTING OF CNC LASER

ENGRAVER/CUTTER

A REPORT
submitted in partial fulfillment of Requirement of the degree for

Bachelor of Technology
In

Mechanical Engineering
For the Academic Year
2023-2024

Submitted by

1.Shashwat- 2057097
2.Kaushic Kumar- 2057136
3.Saurav Kumar- 2057095
4.Rajeev Ranjan- 2057133
5.Premkar Pandey- 2057153
6.Aakash Gupta- 2057117

Under the guidance of

Prof. Sudipta Roy

Assistant professor
Department of Mechanical Engineering
 ABSTRACT
This project focuses on the design, construction, testing and application of a 3 axis Computer
(CNC) laser engraver. The proposed work in this project is to explore the potential of CNC
laser engraving technology and is centered as well as inspired on findings that demonstrate
the use of automated CNC machinery accelerates the repair processes, updates equipment
capabilities, and significantly decreases overall costs. The prototype introduces a cost-effective
solution to developing a 3D model of a CNC machine using a laser engraver, emphasizing
simplicity to avoid issues of defects and high costs. The focus was on designing parts that are
easily accessible to consumers or can be self-produced to enhance usability in production. A
CNC system for precise control of the laser engraving process and the utilization of powerful
laser for accurate engraving on a range of materials. Examining the impact of engraving by
changing different parameters such as laser power, speed, different materials and overall
analysed it on two output parameter that is surface roughness and MRR. The selection of the
hardware was also considered with the ability for swift replacement in the field in mind.
Furthermore, exploration and incorporation of user-friendly open-source software was also
made for input in design and control of machinery.

i
 DEPARTMENT OF MECHANICAL ENGINEERING
HERITAGE INSTITUTE OF TECHNOLOGY

CERTIFICATE OF RECOMMENDATION

I hereby recommend that the report presented under my supervision by Mr. SHASHWAT, Mr.
KAUSHIC KUMAR, Mr. SAURAV KUMAR, Mr. RAJEEV RANJAN, Mr. AAKASH
GUPTA, Mr. PREMKAR PANDEY entitled "DEVELOPMENT AND TESTING OF CNC
LASER ENGRAVER/CUTTER" is a bona-fide record of the work carried out by him in the
Metal Forming Laboratory, Department of Mechanical Engineering, Heritage Institute of
Technology. The contents of this project report, in full or in parts have not been submitted to
any other University or Institute for the award of any degree or diploma and be accepted in
partial fulfilment of the requirements for the degree of Bachelor of Technology in Mechanical
Engineering.

Project Mentor,
Prof. Sudipta Roy,
Assistant Professor,
Mechanical Engineering Department,
Heritage Institute of Technology

Countersigned

Head Of Department,

Mechanical Engineering Department,

Heritage Institute of Technology

ii
 ACKNOWLEDGEMENT

We would like to express our sincere gratitude to all those who have contributed
to the successful completion of this project.
First and foremost, we extend our deepest gratitude to our project supervisor
Prof. Sudipta Roy, whose guidance, expertise, and invaluable feedback were
instrumental throughout the project.
We acknowledge the immense support of the faculties and Technical Assistants
especially Anupam Biswas sir, Dept. of Mechanical Engineering, Heritage
Institute of Technology, whose assistance was critical in making this project a
reality.
Lastly, we are indebted to our friends and families and co-members of the team
for their support and encouragement during this endeavour.

Mr. SHASHWAT …………………………….

Mr. KAUSHIC KUMAR ……………………..

Mr. SAURAV KUMAR ………………………

Mr. RAJEEV RANJAN ………………………

Mr. AAKASH GUPTA ………………………

Mr. PREMKAR PANDEY …………………..

iii
 NOMENCLATURE

CNC- Computer Numerical Control

MDF- Medium density firewood
GRBL- Grand Rapid Branch library.
LASER- light amplification by stimulated emission of radiation
G-Code- Geometric Code
SMPS- Switched Mode Power Supply
MRR – Material Removal Rate

iv
 LIST OF FIGURES

SL NO. DESCRIPTION OF FIGURE PAGE NO.

1. Assembly Drawing 4
2. V-Slot extrusion bar (400mm) 5
3. V-Slot extrusion bar (500mm) 5
4. End connector/Base 6
5. Side-roller Connector 6
6 Power screw 7
7 Laser holder part 2 7
8 Laser and stepper motor holder Part 3 8
9. Flow chart of electronic connection 10
10. Flow chart of software integration 11
11. Laser 11
12. Stepper Motor 12
13. Stepper Motor Controller 12
14. CNC Shield 13
15. Arduino Uno 13
16. Slot Extrusion Bar 13
17. SMPS 14
18. Jumper Wire 14
19. Gantry Wheels 14
20. Bore Timing Pulley 15
21. Belts 15
22. Nuts and Bolt 15
23. Shape Connector 16
24. Flow chart of operation 17
25. PVC End connector/Base 18
26. Side connector with gantry wheel assembly with belt and 18
pulley connected to Stepper motor.
27. Front View and Top 19
28. Isometric View 19
29. Full Connections 19
30. Module Assembly 20
31. Laser With Module Assembly 20
32. Real Text Image 23
33. Graph of Penetration Test (Min Focal length) 26
34. Graph of Penetration Test (Max Focal length) 26

v
 LIST OF TABLES

Sl No. DESCRIPTION OF TABLE PAGE NO.

1 Table-1 21

2 Table-2 21

3 Table-3 21

4 Table-4 21

5 Table-5 21

6 Table-6 22

7 Table-7 22

8 Table-8 22

9 Table-9 22

10 Table-10 22

11 MRR Test 23

12 Accuracy/Efficiency Test 24-25

vi
 CONTENTS
Page No.
Abstract i
Certificate of Recommendation ii
Acknowledgement iii
Nomenclature iv
List of Figures v
List of Tables vi
1. Introduction 1-2

2. Objective 3
3. Chapter 1: Methodology 3
1.1 Construction 3
1.1.1 Design Analysis 3-9
2-D Part Drawing 5-8
Stress Analysis 8-9
1.1.2 Electronic System 10
1.1.3 Software Development 10-11

1.2 Components 11-16

4. Chapter 2: Operations 16-17

5. Chapter 3: Advantages 17

6. Chapter 4: Fabrication 18-20

7.Chapter 5: Testing and Results 21-25

8.Chapter 6: Discussions 26-27

9. Chapter 7: Future Scope of Work 28

10. Conclusion 29

8. Reference 30

vii
 INTRODUCTION
Light Amplification by Stimulated Emission of Radiation (LASER), functions as a device that incites
atoms or molecules to release light at specific wavelengths, intensifying that light and resulting in a
focused beam of radiation. Simultaneously, the Computer Numerical Control (CNC) system has
transformed the manufacturing industry by facilitating and improving automated, consistent, precise,
accurate, flexible, and intricate machining processes.

The CNC laser engraver has a rich history. In 1965, the first laser cutting machine was utilized to create
holes in diamond dies. Two years later, the British introduced laser-assisted oxygen jet cutting for
metals [1]. By the early 1970s, this innovation was utilized to cut titanium for aerospace applications.
Simultaneously, CO2 lasers were utilized to cut non-metals like textiles due to their insufficient power
for metals. Over time, various laser types, including Plasma lasers, emerged. Initially, designs on ferrous
and non-ferrous materials were achieved manually using cutting tools, which was time-consuming,
imprecise, and expensive. To address these challenges, the 3-axis CNC laser engraver or cutter was
developed. This technology represents a significant advancement at the intersection of engineering,
technology, and manufacturing. It utilizes a computer-controlled laser beam that is focused by a lens
onto the target surface for engraving purposes.

The significant industry corporations have the ability to utilize CNC laser engraving and cutting
machines with more financial budgets. On the contrary, smaller-scale industries face challenges in
affording such high-end technology, resulting in a significant gap in accessibility. The main objective
of this project is to bridge this gap by constructing a cost-effective CNC laser engraver/cutter using
easily obtainable components from the regular market. This machine aims to match the efficiency and
productivity of industry counterparts. Experimentation will involve testing its versatility on various
materials by adjusting different parameters such as laser frequency, beam angle on objects, speed,
vertical distance, among others.

During their study, Genna et.al [2], explored how the process parameters impact both the material
removal rate (MRR) and surface roughness when engraving C45 carbon steel. They employed a 20W
laser with a wavelength of 1070 nm.

Agalianos et.al [3] studied the influence of laser engraving on surface quality. Numerous other studies
have experimented with various parameters, prompting this project to broaden the scope and evaluate
factors like the intensity of the laser beam striking the object.

According to Kasman et al. [4] laser engraving proves to be the most effective method for shaping tough
materials with intricate designs. The research focuses on assessing the workability of hard metal created
through powder metallurgy and proposes a fresh perspective on engraving P/M metals using lasers.

Štefan Koprda et al. [5] discusses the potential for developing a prototype of a cost-effective CNC
machine with a laser engraver using an Arduino platform. The paper introduces a budget-friendly
solution aimed at creating and refining a 3D model of a CNC machine integrated with a laser engraver.
The objective was to streamline the design by reducing the number of to not only mitigate costs but also
address issues related to performance optimization for practical production applications.

A.P. Singh et.al [6] discusses the development and testing of affordable CNC machine using the
TAGUCHI method to determine optimal process configurations. Subsequently, ANOVA analysis was
conducted to determine the specific impact of each variable on performance characteristics. The
findings revealed that a cost-effective CNC laser engraver could be manufactured to work with various
materials of different dimensions, adjusting parameters such as scan speed, power, and wavelength for
materials like wood, steel, plastic, and more.

1
Jeet Patel et al. [7] analysed and created a prototype of a 3D printer operating on the same fundamental
principle as CNC. They manufactured a small object like a gear and deliberated on the benefits of such
machinery.

Md. Ehteshamur Rahman et al. [8] presented a compact design of affordable multi-purpose computer
numerical control (CNC) laser engraver on their paper.

After examining, Rashid Khalid Hilal Al Habsi et al. [9] recognized the growing need for compact3-
axis CNC engraving machines with components across various industries, it has become evident that
achieving a balance between flexibility and efficiency is crucial in the production of small parts. This
optimized manufacturing approach not only lowers overall costs but also remains cost-effective for
individuals and small businesses.

Mehra, R et.al [10] provided research that introduces a cost-effective laser engraving machine
prototype that has been successfully used on different materials like Glass Fiber Reinforced Plastics
(GFRP composites, plastics, wood, and cardboard. The setup effectively produces the desired profile,
contour, information, and various drawings. Furthermore, the laser engraving system developed
exhibits high precision and processing efficiency.

Zhenshuo Yin et.al [11]emphasized on accuracy of the kinematic model and parameter measurements
as its vital aspects that determine the processing quality of LEMT.

Antonin DURNA, et.al [12] discussed that 3D printer was adapted for laser engraving and material
cutting in the study. This innovation involves merging laser engraving and 3D printing technologies.

K. Prashant et.al [13] in their prototype employed 2.5 W diode laser is for engraving various materials
by bringing together advanced software and hardware such as Inkscape, Maker Base, GRBL controllers,
and microcontrollers. This integrated setup facilitates the execution of the final engraving process.

Sachin Patel et.al [14]This paper presents the recent research conducted by the authors on laser
engraving of Stainless Steel 316. Laser engraving involves the machining process of engraving material
using a laser.

Lin li [15] discusses on examination of high-power diode laser materials processing summarizing the
practical uses of these lasers, encompassing activities such as soldering, surface alterations (like
wetting, glazing , cladding, and hardening modifications)etc.The analysis of high-power diode lasers
for materials processing emphasizes benefits like improved surface quality, reduced heat-affected areas,
enhanced beam absorption, superior morphological attributes, increased consistency and repeatability
in outcomes, reduced incidence of cracks, and minimized porosity formation. Limitations of high-power
diode lasers consist of challenges related to high beam divergence (hampering precise focusing on small
beam sizes), beam absorption affected by the color of workpieces, and limited ability to achieve highly
powerful short-pulsed beams directly (Q-switching).

Janez Diaci et.al [16] introduces an innovative approach for quickly adaptably laser marking and
engraving surfaces that are tilted, curved, or have freeform shapes.

Mingwei Li et.al [17] discusses on laser micro-processing of semiconductor materials like sapphire and
silicon has garnered increasing interest in recent times.

As earlier stated, the disadvantage of current industrial CNCs is their high price. That is the reason that
low-cost solutions are preferred with comparative specification to market leaders.
The project/Prototype could be used for detailed engraving designs on various material like MDF, wood,
paper, leather, bamboo, plastic, rubber, etc.

2
 OBJECTIVE
Upon examination of the challenges within the automation sector, several issues arise including cost,
efficiency, and component availability in the market. As previously mentioned, the primary drawback
of current industrial CNCs is their steep pricing. This necessitates the exploration of more affordable
alternatives that can offer comparable specifications to industry leaders. However, simply reducing
costs may not fully meet the machine's requirements; factors such as efficiency and versatility must also
be considered. Therefore, an assessment of the versatility of utilizing a CNC laser engraver/cutter on
different materials becomes essential. This evaluation involves the analysis by changing the parameters
such as speed, power of laser, changing-Z axis length and calculation of two key parameters: Material
Removal Rate (MRR) and Surface Roughness. Consequently, this project is dedicated to the
development and testing of a laser engraver/cutter on various materials. In general, CNC laser
engravers/cutters have the capability to intricately engrave designs on a range of materials including
MDF, wood, paper, leather, bamboo, plastic, and rubber.

CHAPTER 1: METHODOLGY

1.1 Construction

1.1.1 Design Analysis- The core component of the machine tool is its structure, uniting all machine
parts into a cohesive system. To ensure stability, V-slot aluminum extruded bars is utilized for the
machine bed. Opting for an H-shaped design over traditional L-shapes will provide increased working
space and structural strength. Positioned 100mm above the ground with end connectors, the structure is
primed for analysis based on essential parameters like travel length. Travel length pertains to the X, Y,
and Z axes. The X axis moves horizontally, the Y axis vertically, and the Z axis manually using a screw
bar. The workspace dimensions measure 500 x 400mm.

Following the design draft, the structure undergoes evaluation to meet design requirements with
minimized joints and various materials, ensuring cost-effectiveness and anticipated efficiency levels.

3
Fig-1 Assembly Drawing

4
2D-Part Drawing-

Fig-2 V-Slot extrusion bar (400mm)

Fig-3 V-Slot extrusion bar (500mm)

5
 Fig-4 End connector/Base

Fig-5 Side-roller Connector

6
 Fig-6 Power screw

Fig- 7 Laser holder part 2

7
 Fig-8 Laser and stepper motor holder Part 3
Stress analysis-

The v-slot aluminum extrusion was selected for this particular project because of its cost-effectiveness
and specific properties essential for the prototype, setting it apart from alternative materials. In
comparison to iron with identical measurements, the chosen aluminum material is lighter due to its
lower density relative to iron. Additionally, aluminum was preferred over copper mainly due to its
reduced cost. These extrusions provide excellent strength, resistance to corrosion, and come in various
shapes and sizes. Wood was excluded from consideration due to the difficulties in creating precise v-
slots in this material. Consequently, the choice to utilize v-slot aluminum bars was influenced by factors
like stability and ease of movement within the prototype.

PVC material was decided for the end connectors/base because of its compressive strength and stability.

There are basically three types of loads acting on the End connector/Base–
1. Static loads- It is basically the weight of machine component, tool head and work piece.
2. Dynamic loads- It is the forces resulting from rapid movements and acceleration.
3. Thermal loads- when we will be using laser then due to temperature variation thermal stress
will be generated.
Analysing all three types of loads is essential to identify potential failures resulting from these diverse
loading conditions.
Here,
Weight of 500 x 400mm aluminium extrusion = 2.33kg

Weight of laser + laser holder = 0.2kg + 0.25kg =0.45kg

Weight of gantry rollers and its holder = 0.1 x 3 = 0.3kg

8
 Stepper motor weight=0.24 x 3= 0.72kg

End connector=0.1 x 2 = 0.2kg

So, total static load=2.33kg+0.45kg+0.3kg+0.72kg+0.2kg

= 4kg
As we know,
Maximum revolution of stepper motor =3000rpm
So,
𝜋𝐷𝑁
𝑣=
60
3.14 × 0.005 × 3000
𝑣=
60
𝑣 = 0.785𝑚/𝑠
Where,
D=diameter of stepper motor spindle

In unit sec, Maxm load= 4 × 0.785

= 3.12 N
Load due to gravity = 4 × 9.81 = 39.24 N
Total load acting on the 4 base/End connector = 39.24+3.12 = 42.36 N
Also, PVC compressive strength = 6.79 Mpa
Now, F = 𝐴𝑟𝑒𝑎 × 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
Area= 𝜋𝑟 2 ( r= radius of PVC material used =21.5 mm)
= 3.14 × 21.5 × 21.5 = 1451.4 mm2
Therefore,
F=1451.4 × 6.79 = 9855.44 N
As, load acting on the End connector/Base < Maxm load that can be beared by End connector/Base
42.36N < 9855.44 N
Therefore, it can be concluded that load is encountered by end connector in very efficient way.
To encounter dynamic loading, we are using gantry wheel which provide smooth and very less friction
due to which very low amount of dynamic load can generate and also, we will program the CNC
controller to use gradual acceleration and deceleration profiles to reduce sudden, jarring movements
that can generate dynamic loads. This prevention method will keep dynamic load in permissible limit.
When laser is in running condition, then thermal expansion of the material takes place. This could be
controlled and reduced by heat dissipation by fan on the laser (which is part of the laser itself) that will
reduce the temperature around the working of laser light and material.

9
1.1.2 Electronics System- Now, the circuit making includes connections between the Arduino uno,
motor driver, stepper motor controller, stepper motor, limit switches, battery-12v. The circuit diagram
is given below:

Fig 9- Flow chart of electronic connection

1.1.3 Software Development- Now thirdly, there is coding part which will be done through GRBL
software installation in the Arduino and then sending g-code through computer to Arduino. The software
is needed to change image into understandable language in Arduino so, image processing software such
as -Inkscape is used. Through this the CNC will systematically and accurately engrave the design
commanded through input command.
GRBL is a popular open-source firmware that converts G-code commands into precise movements for
CNC machines, including laser engravers. One can install GRBL on Arduino, and it will manage the
motion of ones stepper motors.
Laser GRBL is a popular, open-source control software designed specifically for laser engraving. It
provides a user-friendly interface for sending G-code commands to the GRBL firmware and controlling
the laser engraver.
Now design software such as Inkscape allows one to create scalable vector designs suitable for laser
engraving.

10
 Fig-10 Flow chart of software integration

1.2 Components

Laser engraver: - Laser engraving machines are intriguing instruments utilized to imprint designs
onto a variety of materials such as wood, metal, glass, acrylic, and more. These machines operate by
employing a powerful laser beam to eliminate material from the surface, resulting in precise and
intricate engravings.

Specification-

• Item dimension: 12 x 6 x 6 cm
• Weight of the laser: 200g
• Laser input power-20 W
• Wavelength- 450 nm
• Laser output power- 4W
• Electrical power: 5V-12V
• Material: leather, plastic, acrylic, bamboo and so on

Fig-11 Laser
It comes with changeable pulse with modulation; hence all these specifications is suitable for our
project.

Stepper motor: - An electric motor known as a stepper motor is characterized by its ability to rotate
its shaft in incremental steps, moving a set number of degrees at a time.

Here in this project NEMA-17 is used.

11
Selecting stepper motor over servo motor

• Stepper motor have simple design and control.

• This works on open control loops so no feedback is required.
• Stepper motors, as they do not necessitate feedback, utilize more affordable magnets. They
offer moderate torque at low speeds, resulting in lower power consumption at zero speed.
Consequently, stepper motors are generally more cost-effective compared to servo motors.
• The stepper motor-17 has a step angle of 1.8 degrees and is widely available in the market at a
lower cost.

Fig-12 Stepper Motor

Stepper motor controller: -

A stepper motor controller is a tool utilized for accurately managing the motion of stepper motors.
These motors are electrical-mechanical gadgets that transform electrical pulses into distinct mechanical
motions, which makes them well-suited for tasks necessitating precise placement, such as 3D printers,
CNC machines, robotics, and automated systems.

Fig-13 Stepper Motor Controller

CNC shield: - A CNC shield is a modular electronic device commonly utilized in DIY CNC
(Computer Numerical Control) projects. It acts as a connection point between a microcontroller board,
such as an Arduino, and stepper motor drivers, allowing the management of stepper motors for precise
movement control in CNC applications.

12
Specification:

• Product dimension: 9.7 x 9.4 x 3.3 cm

• Number of slots: 4
• IO pins for single stepper motor: 2

Fig-14 CNC Shield

Arduino Uno: - Arduino as an open-source platform designed for constructing electronics projects,
comprising a physical programmable circuit board and software called the Integrated Development
Environment that operates on a computer.

Specification-

The board has 14 digital I/O pins (6 analog I/O pins)

Fig-15 Arduino Uno

V slot aluminium extrusion bar: - V-Slot is a high-quality extruded aluminium profile building
block.

Specification-
Length – 400mm and 500mm
Width- 20mm
Thickness-20mm
Compressive strength-137 to 345 MPa

Fig-16 V-slot Extrusion Bar

SMPS: - Arduino serves as an open-source platform designed for constructing various electronics
projects. It comprises a physical programmable circuit board along with software known as an
Integrated Development Environment, which operates on your computer.

Specification: SMPS are categorized based on supply input and output voltage, and the main four
groups are AC, DC, DC-DC, and DC-DC.

13
Connection of 3V, 5V, 12V

Fig-17 SMPS

Jumper wires: - Jumper cables are utilized to establish connections between components on your
breadboard and the header pins of your Arduino. Utilize them to link all of your circuits together.

Fig-18 Jumper Wire

Gantry Wheel: Gantry wheels play a vital role in the movement and operation process. These wheels
are specifically crafted to bear heavy loads, facilitating smooth and efficient motion along V-Slotted
aluminium bars where the lasers are positioned.

Fig-19 Gantry Wheels

14
Bore timing pulley: Timing pulleys with bores are gear wheels that mesh with the teeth of a
corresponding timing belt to transfer power throughout a given operation.

Fig-20 Bore Timing Pulley

Belt: Belts serve functions such as providing motion, transferring power efficiently, or monitoring
relative movement. They are wrapped around pulleys and may include a twist between them, allowing
for non-parallel alignment of the shafts.

Fig-21 Belts

Nut and Bolts: Nut and Bolts that are used such as M4*0.5, etc.

Fig-22 Nuts and Bolt

15
L-shape connector: Used to connect the ends of the v-slot aluminium extrusion.

Fig-23 L-shape Connector

Chapter 2: OPERATIONS
The prototype possesses three degrees of freedom: X and Y movements occur on the v-slotted aluminum
bar using a roller and belt-pulley mechanism. For Z-axis movement, which houses the laser module,
manual adjustments are made in the vertical direction with a screw bar.

Essentially, the CNC system features three degrees of freedom along the X, Y, and Z axes. The power
source, a SMPS, links to an Arduino board, which in turn connects to a stepper motor controller
responsible for operating the stepper motor. This SMPS also powers the laser, which is additionally
linked to an Arduino Uno.

By following these steps, it becomes possible to engrave the desired design onto the material's surface.

16
 Fig-24 Flow chart of operation

CHAPTER 3: ADVANTAGES
1. Precision and Accuracy: CNC systems provide exceptional precision and accuracy
when engraving, enabling the creation of intricate and detailed designs.
2. Complex Geometries: These systems are capable of engraving elaborate shapes,
patterns, and text that would be difficult to achieve manually.
3. Speed and Efficiency: CNC laser engravers operate quickly, making them highly
efficient for projects on a large scale.
4. Automation: Once the machine is programmed, it can function independently,
minimizing the need for constant human involvement.
5. Versatility: This 3-axis CNC laser engraver can handle a wide variety of materials such
as wood, metal, glass, bamboo, and acrylic, making it versatile for different
applications.
6. Cost-Efficient: This CNC laser engraver is significantly more affordable compared to
conventional models available in the market, being only half to two-thirds of the price.

17
 CHAPTER 4: FABRICATION
Constructing the base

Fig-25 PVC End connector/Base

Framing the side connector

Fig-26 Side connector with gantry wheel assembly with belt and pulley connected to Stepper
motor

18
Final X-Y axis assembly

Fig-27 Front View and Top

Fig-28 Isometric View

Final Assembly

Fig-29 Full Connections

19
Laser Holder/Adjustment

Fig-30 Module Assembly

Fig-31 Laser With Module Assembly

20
 CHAPTER 5: TESTING AND RESULTS
The prototype is tested on 3 different-test to get the overall synopsis of the
power of laser, accuracy and and material characteristics.
Penetration Test:
Distance between the laser and workpiece: 50 mm
Thickness of workpiece: 3 mm
Material Focal Length Intensity (%) Time (min)
100 1.0
Plywood Maximum 75 1.15
50 2.0
25 2.50

Table-1

Material Focal Length Intensity (%) Time (min)

100 0.166
Fabric (Jeans) Maximum 75 0.25
50 0.33
25 0.42
Table-2
Material Focal Length Intensity (%) Time (min)
100 11
Composite Maximum 75 15+
(Jute + Sisal) 50 15+
25 15+
Table-3

Material Focal Length Intensity (%) Time (min)

100 1.0
Bamboo Maximum 75 1.35
50 1.45
25 2.05
Table-4
Material Focal Length Intensity (%) Time (min)
100 1.20
Acrylic Maximum 75 1.40
50 1.55
25 11

Table-5
21
Distance between the laser and workpiece: 10 mm
Thickness of workpiece: 3 mm

Material Focal Length Intensity (%) Time (min)

100 0.88
Plywood Minimum 75 1.04
50 1.10
25 1.46

Table-6

Material Focal Length Intensity (%) Time (min)

100 0.4
Fabric (Jeans) Minimum 75 1.48
50 2.25
25 4

Table-7

Material Focal Length Intensity (%) Time (min)

100 16
Composite Minimum 75 20+
(Jute + Sisal) 50 20+
25 20+

Table-8

Material Focal Length Intensity (%) Time (min)

100 0.46
Bamboo Minimum 75 1.00
50 1.20
25 1.50

Table-9

Material Focal Length Intensity (%) Time (min)

100 1.57
Acrylic Minimum 75 1.56
50 1.53
25 4

Table-10
22
Material Removal Test:

Material Initial Weight Final weight Time taken MRR

(gm) (gm) (min) (kg/min)
Jeans 46.614 46.287 4 0.08175
Bamboo 12.492 12.422 1.30 0.05384
Plastic 6.204 6.104 4 0.025
Wood 38.518 38.311 4 0.05175
Leather 58.353 58.210 4 0.03575

Table-11 MRR Test

Accuracy Test/Efficiency Test:

The main aim of any prototype is to address the specific problem it was created for. One crucial
factor that prototypes are evaluated on is their efficiency. The key question that arises is
whether they are sufficiently accurate during testing.

Consequently, the prototype undergoes an efficiency test by varying two main parameters:
Speed and Intensity (PWM). Three different speeds and intensities are chosen for this purpose.
Subsequently, a comparison is made between real uploaded images in the software and the
extruded images.

Fig-32 Real Text Image

23
SPEED (mm/s) INTENSITY Extruded Samples

100%

75%`
500

50%

100%

75%
1500

24
 50%

100%

2500
75%

50%

Table-12 Accuracy/Efficiency test

25
CHAPTER 6: DISCUSSIONS

Fig-33 Graph of Penetration test(Min focal length)

26
Fig-34 Graph of Penetration test (Max focal length)
During CNC setup, various challenges like unclear instructions, alignment issues, and calibration
problems often arise. Following the testing phase, the machine undergoes testing on different materials
such as wood, bamboo, jeans, acrylic, and composite. The testing involves determining the time
required for the laser to cut a set thickness of these materials for a specific length, as well as calculating
the Material Removal Rate (MRR) for each material that shows the property of materials tested where
most material was removed from jeans followed by wood, leather, plastic. Bamboo was tested for only
90sec because of material shortage.
The analysis indicates that at maximum laser focal length with 100 percent intensity, acrylic required
the most time to penetrate, followed by bamboo, plywood, and fabric, a pattern that persists at 75 percent
intensity. However, when intensity decreases to 50 percent, plywood surpasses acrylic in penetration
time, followed by bamboo and fabric. Further reduction in intensity shifts the sequence back to acrylic
taking more time.
At the minimum focal length of the laser with 100 percent intensity, acrylic once again takes the longest
to penetrate, after plywood, fabric, and bamboo. At 75 percent intensity, fabric and acrylic show similar
penetration times, outpacing plywood and bamboo. With 50 percent intensity, fabric surpasses acrylic,
bamboo, and plywood in penetration time. These trends persist as intensity decreases further.
The composite of jute and sisal were also gone through penetration test where result shows that for
100% intensity it requires 11min to penetrate the material.
The Accuracy/Efficiency shows that at 2500mm/s at 100% intensity gives the best result in comparison
with the real text image.

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 CHAPTER 7: FUTURE SCOPE OF WORK

• The cost of the prototype could be more reduced with mass production.
• With more increase of efficiency, it may come up to industry standards.
• With improvements in design more vibrations could be reduced, leading to increase in
accuracy.
• With few changes to design of prototype, that is attaching claw like structure or vacuum
tubes to the base could lead the prototype using at any places even on the walls of the
room.
• With more power of laser used, can lead to engraving in hard surfaces too.
• By changing Arduino and CNC-shield to heavy duty microcontroller and CNC-shield,
will lead to more advance CNC-laser engraver/cutter.
• It can be used to check the surface roughness, MRR of other different composites, hence
can be used for materials research.
• As automation is the key to production, the prototype with industry standard efficiency
is the solution.

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 CONCLUSION
Throughout the entirety of the project's evolution, the decision to adopt the H-shaped model
proved to be successful in enhancing stability compared to the L-shaped model. Combining
hardware and software components effectively optimized vibrational instability, with the
utilization of petroleum gel reducing friction and circular bases aiding in system stabilization.

In the software realm, Inkspace and OpenBuilds Compiler were utilized to convert images into
G-code and control the prototype, which underwent testing in three different scenarios:
Penetration test, material removal rate assessment (MRR), and accuracy/efficiency evaluation.
Notably, jeans exhibited the highest material removal rate, while the system demonstrated
optimal efficiency at higher intensities and speeds.

Consequently, it can be inferred that the prototype is well-suited for educational institutions,
small-scale industries, and domestic applications. Further enhancements could potentially
position the prototype as an optimized solution for larger industrial settings.

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