Laser Module Adapter w/ Airblast - for Bosch Colt 1hp Router Mounts

thingiverse

Changing the tools on an MPCNC Primo is a bit of a task. So I designed this thing to quickly swap in a laser diode module without having to remove my Bosch Colt 1hp router mount. It simply slides into a 1hp Colt mount like the router itself. It includes a convenient holder for a 1/8" OD air blast tube for improved cutting results. If you are looking for a 1hp Colt mount for your MPCNC Primo, I designed one with a vacuum flange here: https://www.thingiverse.com/thing:4632040 I optimized this design to work best with doide/lenses that cut with 1-3" focal length (most commonly available laser modules cut best within this range). Cutting at 1" focal length with the adapter cup slid all the way down, the laser point is mostly covered by the router mount vacuum flange for added safety. For better safety when using longer focal lengths, slide the adapter upwards to keep the bottom of the gantry as low as possible, or attach some extension to your vacuum flange. The position of the air-blast tube is east to adjust with a single set screw to accommodate various focal lengths. This thing is also designed so that when fitted with a laser that has a 33x33mm cross section heatsink, the lens will be centered in the same place the router bit would be. The mount will also fit larger modules, as long as the bolt spacing is 20x40mm. For example, 40x40mm wide modules will fit with the lens offset 3.5mm from where the router bit would be. Similarly modules smaller than 33mm will be offset in the opposite direction. The air blast tube is located behind the mounting plate so it does not interfere regardless of the size of your laser module. Despite what your budget may be, instant retina damage is never worth the risk. Always have everyone in the room wear proper eye protection when operating laser cutters/engravers. Especially, do not cheap out on the safety glasses; buy OD6 or higher rated filters from a well known brand. BOM: 1@ cnc router w/ a Bosch Colt 1hp router mount 1@ laser diode module w/ 20x40mm mounting pattern (I use an Oxlasers 3.5W output unit) N@ pairs of OD6 safety glasses 1@ printed Colt laser adapter (either 4mm or 7mm air-blast hole) 4@ M3-8 bolts 1@ M3-12 bolt (or longer) 1@ ~10" length of 1/8" OD copper or aluminum tubing (optional for air blast) ...or~10" length of 1/4" OD poly air tubing (also optional) 1@ 1/4" length of filament (any stiff stuff, not TPU... also optional) Printing: No supports are required. Laser doides can get very hot. Print with PETG filament or similar to prevent warping of the mount. Assembly: Secure your laser module using the four M3 allen head bolts threaded into the existing holes on the module (use threadlocking compound). Bend and shape the end of the air blast tube as desired (the more parallel to the laser the better). Insert the air blast tube from the bottom hole. Insert the 1/4” long piece of filament into the M3 hole on the top (cut both ends square). Secure the air tube in position by snugging down the M3-12 bolt on top of the piece of filament. Insert the adapter cup into your Bosch Colt router mount. Adjust the cup vertically as needed to get the lens height where you want it, then tighten the router mount to secure the cup. With the adaptor slid all the way down using an OXlaser 3.5w module and the Colt mount linked above, the lens is flush with the bottom of the z-axis on an mpcnc primo. I added an updated version with a larger 7mm diameter hole for the air-blast tubing, which allows me to run the 1/4" poly air line right up within inches of the cut. This reduces friction losses and allows quiet low pressure compressors to run cooler. The version with 4mm hole means a longer run of 1/8 OD tubing. From my experience it cuts just as well, however I have to reduce bypass air on my compressor which makes it run hotter. The 7mm version allows me to get the same air at the nozzle with more bypass air at the compressor, which helps keep the compressor much cooler.