Recently, my access to a laser cutter has gone from hopeful, to occasional, to every (laser filled) day! We picked up a brand new Pro LF Series 36×24 CO2 Laser from Full Spectrum Laser here in Las Vegas. The build quality is solid and installation and calibration was a breeze.
After some initial requisite etching of Einstein’s face onto acrylic blocks, I decided to turn my attention to something more practical. I fired up Solidworks and used the specs provided by Apple for the iPhone 4S. I wanted to be able to prop up my phone while using Facetime, but not obstruct the screen. Using clear acrylic, I cut out a shape that allowed me to slide my iPhone through a precisely measured slot… Almost.
As it turns out, this was my first lesson in the challenges of laser cutting. Namely, the problem of the laser kerf, or the width of the beam as it cuts. This is directly analogous to the kerf width of a saw blade when cutting wood. Basically, you need to determine this width for you laser and the media your cutting, then adjust your vector paths accordingly. For internal, closed paths, you want to reduce (subtracting the kerf from the radius of a circle, for example) and for perimeter paths, you want to expand your design by the kerf width.
After some fairly simple adjustments, I was able to get a perfectly fitting iPhone 4S stand made of clear acrylic that can be adjusted to any position along the iPhone body and stays put using friction alone. Not a bad way to spend 30 mins to create something useful.
Oh, and here’s Einstein!
