Tech Today: Laser Printer Fab for the 12-Volt Industry

FOREWORD BY JOEY KNAPPWORDS BY ERICK MARKLAND

This article wraps up the final in our series on advanced fabrication tools that are being utilized in our industry. So far we have looked at 3D printing and CNC machining. This installment rounds out the fab trifecta with a look at lasers. Not on the heads of sharks, but in the shops and hands of talented fabricators.

One such fabricator agreed to share his recent experiences with the purchase of his laser. I am pleased to share with everyone a little insight from the 2018 Mobile Electronics Installer of the Year, Runner Up, Erick Markland of Markland Designs of Atlanta. I have watched Erick’s work over the years and have been continually impressed with not only his fabrication talents, but also his positive attitude. It was nice to see him recognized, and I expect we will be seeing even more of him in the future!

Why did you choose a laser printer for Markland Designs?

I chose to purchase a laser printer for Markland Designs mainly because of its ability to cut very small and detailed parts. One of the limitations with the current equipment in the shop was that I always had to resort to a third-party service when I needed detailed emblems, logos and signage—preferably from a laser shop. By going with a third-party service, it always required extra time and finances I had to account for it in the project’s cost and turnaround time.

Fumes and dust are something that most shops must battle with in the woodshop, and in my case, this was no different. Any fumes or dust are expelled out of the laser into my high-powered dust-collection system that was fitted especially for the laser. When choosing new equipment, I also must be space-conscious, and the Glowforge Pro measured at 38 by 21 inches, making it a perfect fit because it did not take up vital work space in the shop. It fits on most toolboxes, tabletops, and workbenches.

The Glowforge Pro has a smaller footprint when compared to conventional CNC routers. An added benefit to choosing the Glowforge Pro is its ability to pay for itself with other jobs, such as making keychains, custom parts, templates, trophies and other engravable items. I do not plan on replacing my routers and tables—the Glowforge Pro laser printer just allows me to cut items I cannot safely cut by hand.

Here is the laser cutting custom rings that will attach to the magnet structure of a Hybrid Audio Technologies subwoofer for a one-of-a-kind look.

There are many 3D laser printers on the market, so what were the deciding factors for choosing a Glowforge Pro 3D Laser Printer? I researched many 3D laser printers. I ultimately chose the Glowforge Pro because of its overall size, the unlimited cutting size due to the pass-through it has, the price and the availability of technical support regarding any issues with the laser.

There is also a built-in camera allowing me to visualize the work-bed on my laptop and that helps with precision alignment and cutting. This particular laser also has an app that can be downloaded to most smartphones and tablets. If I’m not near my laptop, I can send a design from my iPad, which is extremely convenient. The ability to scan and trace parts in the work-bed is an added benefit as well.

Compared to some printers on the market, the Glowforge Pro does not require large power consumption when in use. For the wants and needs of my business, currently the Glowforge Pro is perfect for my application. Later this year, I may add an additional laser if production stays on the current pace.

With such an awesome 3D printer, what software system does it use? And which do you recommend using to maximize productivity?

When I first purchased my laser, I started out using Adobe Illustrator and then transitioned into Fusion 360. I had zero prior experience with either software. I watched many tutorials on the Internet, and joined many live streams asking various questions until I became more efficient with the software.

Many nights after work, I would practice an additional three to five hours designing and cutting using Proofboard material until I became more proficient. This is one of the main reasons I was hesitant about purchasing a laser printer; the design time always seemed like it was very long and intimidating, so becoming proficient was vital to making this huge purchase and investment.

One of the main limitations when using Adobe Illustrator was the level of difficulty when I tried to draw my designs. I found that Fusion 360 was more user-friendly and intuitive to my needs in a design software. There are a ton of software options available and I found that the learning curve was not as fast as I expected, but in the end, if you spend the time using it, you will be more familiar and it really becomes userfriendly, making the options endless.

Here is the laser cutting custom rings that will attach to the magnet structure of a Hybrid Audio Technologies subwoofer for a one-of-a-kind look.

The finished acrylic rings—fresh out of the laser—with the protective tape removed, and ready to be installed on the subwoofers.

What are some pros and cons when comparing a 3D laser printer to a CNC router and a traditional 3D printer?

No matter what equipment is being used, you will have various pros and cons when compared to other options on the market. The pros and cons can be major or minute, depending on what you are looking for and what your expectations are.

For me, the laser printer wasn’t time consuming when compared to a 3D printer, and other pros included accuracy, size, ability to laser print small details and lack of dust accumulation when compared to a traditional CNC router. As of now, the average printing time is 15 to 25 minutes and that’s if I’m printing a project like a panel insert.

Some cons were the inability to print full-sized, three-dimensional parts from scratch or use various filaments like that of a 3D printer. The larger CNC routers have far more cutting space, changeable bits for different profiles and some even having built-in tool changers and the ability to cut at various depths on more material types, such as a thicker acrylic and aluminum which is a plus for the CNC router.

Custom laser-cut rings give the exposed subwoofer a unique appearance, adding detail to the overall project.

We’ve seen the Glowforge Pro in action, so what materials have you used and recommend for others?

Acrylics are what I chose to use most of the time. In addition, I have also used other materials such as MDF along with various other types of wood. Acrylics machine well when dealing with large and small projects, which is a perfect choice with a laser printer. Some vehicles have wood inserts in the doors and dash which creates a very elegant and stylish design in the interior.

Using wood in conjunction with the laser can add a custom touch that blends well with the cosmetics of the vehicle’s interior. Also, a lot of the late model vehicles are using a lot of gloss blacks, silvers and aluminums as accents in the cabin areas. Using two-color or frosted acrylics to match those interiors can give more of a professional detailed appearance.

When adding parts to the interior of a vehicle, I’m always cautious about how they will blend in to the factory panels or overall design. The laser’s software allows me to design and cut prototype parts to make sure they fit and are cosmetically pleasing. I tend to do my prototype mock proofs on Draftboard (or cardboard) because it is more cost-efficient versus wasting expensive resources. With the laser, I have also been able to engrave or score on various leathers and suedes giving my projects a luxurious finish and a custom touch that resembles an original part and design.

The laser has allowed Markland Designs to make custom keychains, logos and signage for local businesses, creating another revenue stream. Every Markland Designs client now receives a custom keychain with their completed project.

How efficient is the Glowforge Pro?

The Glowforge Pro is very efficient for my individual needs. I can draw a design, send it to print and leave it to tend to other projects I have going on simultaneously. The precision of the laser has been superb so far with no issues from the laser itself.

More often than not, if there is an issue with precision, it has been because of how I programmed the design, which goes back to the reason I use Draftboard and cardboard for prototype parts. The file sharing capabilities of a laser printer makes it even more efficient in that I can share designs between myself and others in the industry and edit or manipulate them for my needs or their needs.

I feel that the laser is an employee within itself, so I try to get the most out of each project. Just like a working an employee, when I need him to make a certain sales goal each hour, I expect my laser to make a certain amount of money per job while operating. So far, within the three months since purchasing my laser, it has almost paid for itself with the revenue it created and continues to generate with each passing day.

Are there any limitations to using the Glowforge Pro?

I did quite a bit of research prior to my purchase, so I was familiar with what the Glowforge Pro could and could not do. The only real surprise was the cutting material that this brand of lasers can use. The cutting bed height is lower than some of the other printers on the market. The Glowforge brand interface uses a cloud-based software which can mean delays in getting updates and sending a file to the laser for printing. If the server were ever to go down, the laser printer would be unable to receive any files for printing because it is not hardwired to a device like most traditional lasers on the market which use a USB connection.

For this reason, some laser software programs, such as Lightburn, do not support the Glowforge brand of laser printer, which is unfortunate because it is an extremely nice software program. Hopefully, they’ll come out with a larger version in the future that addresses these issues. With the convenience and the ability to have no prior experience, a novice can design and print in minutes. Therefore, you can’t really go wrong with the laser printer. These were some of the critical issues I found.

Using the laser, I can make custom grilles and accessories. The one shown above is a trim insert for a vehicle featuring a honey-comb designed acrylic grille. Detailed and complex designs like this are the very reason I decided to go with a laser.

One of the benefits of the laser is the ability to engrave and score on high-end materials, such as leather and suede like the photo above. This breaks away from the traditional way of branding, giving a project a more upscale finish.

So far, what are the biggest benefits to the Glowforge Pro 3D Laser Printer?

Having the laser has allowed me to explore deeper into my imagination. At one time, there were things that I could not cut or make by hand, but now I can cut objects to make projects a lot more detailed. I can now give a more OEM appearance. There is nothing worse than having a client request for things to be built, created, or labeled that you physically cannot complete. The laser has allowed me to increase my clientele base because of my added ability to custom fabricate parts as needed for their application.

Also, the laser printer’s versatility has allowed me to explore other revenue-generating opportunities such as making logos for various shops, keychains for local businesses and signage. At this time, a CNC router is not beneficial to the needs of Markland Designs; the laser printer was the ideal choice. I may add a CNC router down the line, but at this time, the laser printer is the most effective and efficient option for me.

Using the same design, I made a slightly larger version with holes at both ends. As an installer growing up and then as a shop owner, I always thought it would be nice to have badges to add to enclosures that I built. Now I had the capability to make those myself! As with the keychains, I filled the badges with epoxy, too. Some of the badges I polished, and some of them I sanded in one direction to offer a brushed aluminum look.

Using Draftboard and cardboard allows for you to physically visualize placement and cuts prior to cutting on the final material. This helps eliminate wasting of costly resources.

Details and labels give a very elegant presentation while actually having form and function. Three years ago, I had to use a label maker to label all parts to ensure serviceability, but now I can add labels and markers right into the design—eliminating wear and tear found with paper labels.