Improve Your Laser Engraving Efficiency with an Automated Jig

The need for automation

Manufacturing items at home tends to be quite a bit slower than what a factory can produce due to the lack of continuous processes and easily repeatable steps. And for element14 Presents host Clem Mayer, this was especially apparent while using his laser engraver, as he was forced to open the enclosure, place down stock, run the machine, and then remove it for every single item. This was far too slow/cumbersome when engraving many identical parts in quick succession, which led him to want a motorized jig that could automate some of the process.

A simple concept

Much of the wasted time stemmed from having to remove and replace fresh stock for an item, so Mayer pursued a design that would allow the machine to stay closed while preparing the next piece for engraving. Eventually, he produced a design that featured a horizontal drum with four sides and a sliding panel on each. Stock could be securely clamped before the jig is placed inside the laser engraver, and when it comes time to work on the next piece, a motor turns the entire drum 90 degrees.

Electronic components

Mayer's prototype began with a Trinamic TMC2100 stepper motor driver and a bipolar stepper motor. An Arduino Uno R3 sends pulses to the driver to rotate the motor 90 degrees only when a rocker switch is hit by the operator. The motor can also be disabled completely to facilitate free movement when a secondary switch is active. A smaller, wired remote with a single switch was constructed as well for easy operation outside the laser's enclosure.

Back to the drawing board

After all of the 3D printed parts and electronic components had been assembled into the jig, Mayer placed it inside his laser engraver for the first round of testing. However, he quickly realized that it was far too tall and interfered with the laser toolhead, so the drum needed a redesign. Ultimately, the spinning, elevated drum idea was scrapped in favor of a flat turntable that could hold up to four pieces of stock in the same orientation. The individual clamps were also replaced in favor of a single magnetic disc that could sit atop the table and keep everything in-place.

Productivity improvements

This project is a great example of how recognizing repetitive tasks can lead to innovative ideas/designs that help decrease the amount of time wasted performing them. And beyond the time savings, Mayer's motorized jig also improved his engraving consistency by guaranteeing every part started in the same place. To see more about how Mayer created and then subsequently iterated on this design, you can watch his video here on the Element14 Presents YouTube channel.