Laser Woodworking
A pioneering craft for the 21st Century.
Each generation, a new technology in
woodworking enables us to work faster, with more precision and more creativity.
Carbide-tipped bits and a whole new set of portable power tools, for example,
have improved how we work and what we build. For the next generation, CNC lasers may also be one of those tools that transform our shops.
I’m a young, 21st Century woodworker.
When Epilog, a maker of CNC Router lasers, asked me to try out the Helix , a
mid-size machine from the Legend Elite series, I jumped at the chance. What can
it do? How does it work? How far can I push it? Dozens of questions came up.
I’ll introduce you to what I found, but one thing I’ll tell you up front:
There’s way more to this technology than meets the eye. After days of
experimenting, I only scratched the surface.
What is a CNC laser?
To understand a CNC laser, think of it
as having two components. First, there’s the CNC Router (computer numerically
controlled) part. You’re probably familiar with CNC Router machines–they’re
common in factories, and are making their way into small woodworking shops,
too. In woodworking applications, a CNC Router usually controls a router. OK,
let’s replace that router bit with a highintensity beam of light–a laser.
That’s the second part of the machine.
Consider a CNC laser as a type of
printer. A computer program moves the machine’s head. But the head shoots a
laser, instead of ink.
What can a laser do?
A CNC laser’s beam essentially heats
and vaporizes the wood it contacts. By adjusting the intensity of the light,
you can determine the depth that it cuts. Usually, the waste is just reduced to
smoke, but when the laser is set on high, you may even create a small flame!
You can fine-tune the depth-of-cut however
you wish, but think of it as having three levels: shallow, medium and deep.
They correspond to three diff erent applications: engraving, relief carving and
pattern cutting.
Lots of folks have bought a CNC laser
for engraving things like nametags, keychains and other quickly personalized
trinkets. It’s a great small business–there’s one in virtually every city in
the country. You can copy your own images or download them from the Internet.
Basically, any image that can be digitized can be engraved.
Cutting deeper into the wood with a
laser creates a three dimensional effect, similar to low relief carving. The
laser is extremely precise. You can create very intricate patterns, perfect for
medallions, awards, moldings or any design that will embellish a project.
Cutting deeper yet, you can go all the
way through a relatively thin piece of solid wood or plywood (up to 3/8"
on the Helix I tested). You’re not making images anymore–you’re making shapes.
Lasers are commonly used to make wooden clock parts, dollhouse furniture,
models, 3-D animal sculptures and more. For workshop applications, you can use
a laser to create extremely accurate plywood templates, based on CAD drawings,
for shaping parts on a router table. You could also use a laser for intarsia,
marquetry or scroll-saw patterns.
That’s just the tip of the iceberg.
There’s a wide community of Epilog users online (www.EpilogLaser.com),
supported and encouraged by Epilog to push the boundaries of what a laser can
do. If you buy a laser for woodworking, or rent time on one, consider yourself
a pioneer. Many applications have yet to be discovered!
How does the laser work?
The Epilog’s laser tube is located in
back of the machine. The beam of high-energy light passes through a series of
mirrors and lenses to a CNC-controlled head, which moves in an X/Y plane (Photo
1). The head moves in a totally sealed and safe compartment containing the
workpiece.
The Epilog interfaces with your
computer much like a printer. After you’ve set up your project in Corel Draw,
the software included with the Epilog (which can be used with a wide variety of
graphic-editing programs), you hit print and bring up a print driver screen,
which Eplilog refers to as the dashboard (Photo 2). The dashboard is where you
make your adjustments. The most important are speed (how fast the laser moves
over your material) and intensity (how strong the laser is, and how deep it
will cut). Once you’ve zeroed in on your settings for a particular project, you
can save and recall them at any time.
What does the Epilog require?
On the hardware side, you’ll need a
computer to run the Epilog. You’ll also need an exhaust system, to remove
particulates and odor from the machine’s exhaust (Photo 3). Most users in a fixed
installation opt to exhaust the fumes out of their shop with a hose or
ductwork, but portable filtration units are available for mobile applications
(like shows and fairs). Most lasers and fi ltration units only need 120-volt
circuits.
On the software side, the Epilog is
designed to empower even a novice computer user to get started creating
quickly. You don’t have to be an expert! Having grown up in the information
age, that part of the operation didn’t faze me, but I was surprised to see how
easy the software was to use at its most basic levels.
Types of Epilog lasers
Epilog has two lines of lasers: Zing
and Legend Elite. The major diff erences between the lines are capacity (the
size and depth of the bed), power (expressed in watts) and resolution (dots per
square inch).
The Zings are entry-level lasers with
smaller beds and lower-power, capable of cutting through 1/4" wood.
The Legend Elite series lasers have a
larger capacity, more powerful beams capable of cutting through wood up to
3/8" thick. Legend series lasers can also engrave at a faster speed than
the Zings.
Both lines of lasers have a
repeatability of ±.0005". Zing series machines engrave up to 1000 dpi; the
Legend series goes up to 1200 dpi.
The Helix I tried out has a 24" x
18" bed, a 60-watt laser. The exhaust system we used is about $3,000.
The bottom line
An Epilog is an investment, no doubt
about it. But it can be the foundation of a profitable small business or the
tool that propels your woodworking to an entirely new level. To find out more
about laser woodworking, contact your local Epilog distributor. He can probably
locate an Epilog in your area and help you contract some work or rent some time
on the machine. After seeing how quick and easy it is to personalize a project
or engrave an intricate design, you just might catch the laser bug. Our
photographer sure did–he achieved some remarkable results.
What A Laser Can Do
Engraving: The Epilog can burn a shallow picture or
drawing on wood. You can reproduce any digital image, including your own photo
or sketch.
Relief Carving: The Epilog can also be set to burn deeper, for
shallow relief carving. A laser can quickly and precisely duplicate intricate
patterns.
Pattern Cutting: Set to full strength, the Epilog can cut all
the way through material. You can duplicate parts large or small, such as these
interlocking puzzle pieces.
Inlay: Using pattern cutting and relief carving
techniques, the Epilog can cut out an inlay and the recess in which it fits.
How It Works
1. The Epilog laser’s head moves like a printer. It will scan back and
forth or follow a continuous line, depending on how it’s programmed.
2. The Epilog’s settings are adjusted in a printer driver window on your
computer. By adjusting rate, frequency, intensity and other parameters, a
variety of materials can be engraved or cut.
3. The laser beam produces smoke and fumes, so you’ll also need an external exhaust
system or a portable filtration unit.
4. The future for CNC laser woodworking is wide open. This
shallow relief carving, based on a photo of a tree, cuts through one layer of
plywood to reveal the layer below. It’s a beautiful effect that we found with
creative experimentation.
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