K40 Laser Pointer Beam Combiner

thingiverse

Inspired by numerous designs that came before it, yet stripped down to its bare essentials. This creation was specifically designed with affordability in mind, utilizing a smaller 20mm x 2.1mm mirror and a compact 6.5mm laser diode. Before mounting the laser, press it firmly into place; however, leave the mirror out of the equation for now to avoid unnecessary complications. The base has been engineered to provide ample space for at least two secure fasteners during the mounting process, ensuring a stable foundation within the housing. Upon my own K40 experience, I discovered that the laser is far from the center of the hole, making it impossible to achieve perfect alignment without tearing down and relocating the mirror mounts. To circumvent this issue, a large base with four slots has been incorporated. Simply secure it firmly in place using two screws to prevent any movement or shifting. To align the system by eye, I plan to carefully burn a spot on some masking tape as a reference point. Keep a fire extinguisher nearby, as the process will likely produce a significant amount of heat and a blurry beam. To minimize damage, work in short bursts until you've achieved the desired alignment. Once centered, mark and drill your holes where you feel would provide the easiest adjustment. The remaining steps should be relatively straightforward. Simply drop the mirror into place, secure it with a clip, and fine-tune the alignment so that the burn spot on your workpiece matches the position of your laser pointer. Please note that this is an ongoing project; I have not yet printed this design, but intend to do so within the next few days. If you happen to print it before me and encounter any issues or successes, please let me know how it worked out for you.