Cloudray K40 Laser Head Mount

thingiverse

I purchased a Cloudray head mount to replace the stock K40 head, which provides two features I desired: air assist nozzle and adjustable focus. I was aware that it wouldn't be a straightforward replacement, and there are 3D printed designs (like https://www.thingiverse.com/thing:3386731) available for purchase or printing to lower it by 8-9mm. However, I didn't have access to a 3D printer, so I decided to create my own laser-cut design! After searching extensively, I couldn't find any existing designs, so I took matters into my own hands and made one myself. I've been using my mount for several projects now, and it's performed flawlessly. The most challenging part is aligning the beam through the small air hole, which isn't specific to this mount. Important warnings for the Cloudray head: * It's longer than the stock head, so be cautious not to ram it into the right and front sides when working with designs larger than A4 size, as this could damage the head and mount. * The air assist connection is at a 90-degree angle, making the above issue even more problematic. * Some sources recommend installing a rubber washer between the lens and the screw-in lens holder to prevent air/smoke from dirtying the lens due to the venturi effect. * You'll need to experimentally determine the new optimal distance from nozzle to material - my targeting design can help with this: https://www.thingiverse.com/thing:4076480. The base plate that supports the head is cut out of the main mount, featuring four holes for screwing in the head. The mount also includes a guide for the air assist tube, although I haven't utilized it yet - I need to install a drag cable first. I use the "scaffold" file to align everything before using difference/intersection tools to create the final path for cutting. ** Warning: Please read this entire section before removing the original head! ** Required: * Screws that match the base of the head * Some skill in laser cutter mirror alignment * You may also want to drill out the laser opening at the bottom to 4mm; 2mm is too difficult to align. * You might need to measure your existing head mount screw positions and adjust them, as every machine is unique - I did mine twice, and it still wasn't perfect. * Suggested: Some kind of alignment test design to run before and after. Assembly instructions: * Cut out all pieces on a working laser cutter - precision isn't crucial. The blue vector engrave line helps with alignment. * Use the four small pieces to mount the cut-out piece in the middle, using two opposing pieces at a time. A little force may be necessary. * Insert the head into the hole, ensuring it's facing the correct direction, and screw it into place. If you want to adjust the height, either add some small pieces under the head or cut the holders at different sizes. * The assembly should hold together reasonably well, but a small amount of glue is a good idea - just keep it out of the head area. * Look at where your existing laser head is positioned and measure the distance from the rail to the center of the beam entrance - you want to maintain that distance. * If you want to run an alignment test to compare results, do so now before removing the existing head. * Remove the existing head and position the new mount parallel to the rail, ensuring the beam entrance center is at the same distance as it was originally - this will minimize alignment issues. * Use the screws on the head to raise the mirror by about 1 mm and then start aligning. A beam guide may be helpful, such as my design: https://www.thingiverse.com/thing:4076480. Other links: This thing has some measurement details in a PDF: https://cdn.thingiverse.com/assets/ac/bf/e2/b9/57/cloudray_k40_parts_Rev01.PDF (https://www.thingiverse.com/thing:3713770/files)