Beam Combiner for K40+

thingiverse

I'm not sure this is so much a remix, but a reimagining of an interesting concept by another designer. I attempted to print, assemble and install the previous version and it just didn't fit my machine - not a surprise as this part was designed in 2017, and here it is 6 years later and the requirements have changed. The design that inspired me to fully recreate this model using similar concepts is: https://www.thingiverse.com/thing:2243280 ERPEL09 came up with an excellent concept, but the details just didn't work for the current machines. The main issue that I found was that the clearance around the moving parts of the K40+ from OMTECH which is quite different than that of the version ERPEL09 was working with. Redesign (changes): 1) The main body that holds the lens is significantly more compact than the original. This facilitates the fit of the body into the correct position after Mirror#1 and keeps the new home sensor for the X axis from bumping against the main body. You MAY have to trim a small amount of material from the top of the lens seat for correct fit. The previous main body flexed significantly from side to side allowing the pointer to get out of alignment if bumped or disturbed while this design is much more rigid. 2) The mounting ring is smaller so that the axis moves to the home position it clears the bottom of the ring. I also redesigned the ring so that it is clamped in place by another ring on the laser tube side of the case instead of friction fit and adhesive. This also allows for a some adjustment in the position of the ring as well as the main body. The ring can also be printed without supports. 3) The laser pointer holder is smaller and more compact, and designed to fit an 8mm pointer. I may release other versions with different diameters - TBD. The adjustment screws are top, bottom, left and right instead of top-right, top-left, bottom-right, bottom left. 4) All screws are matched with heat-set threaded inserts except those from the main body to the ring, which are matched with regular M3 screws in the track of the mounting ring. All parts are printed with ABS, 30% giroid and extensive supports on the inside column of the main body. If your printer is better tuned than mine for overhangs, you may be able to print without supports. Hardware: 4x M2.5x16mm socket head screws, 4x M2.5 6mm socket head screws, 2x M3x8mm socket head screws, 2x M3x2.5mm nuts. 1x M2x6 screw for locking the red laser pointer, 1x M2x4 screw and nylon washer to lock in the combiner lens, 4x 3mm x 15mm springs. (I used 2 springs salvaged from clicker pens and cut them in half). 8x M2.5 heat set threaded brass inserts, 1 M2 insert for the laser pointer holder. The main body is designed for a 20mm Beam Combiner Lense (I ordered from CloudRay). Please feel free to suggest changes in the design if I missed something.