Build a Laser Cutter Fume Extractor

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

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Build a laser cutter fume extractorby Zach on December 29, 2013

Table of Contents

Build a laser cutter fume extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro:   Build a laser cutter fume extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1:   Gather major components and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2:   Cutting disks and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 3:   Install the casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4:   Staple the screen and mesh into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5:   Glue the mesh cylinders down to the base with silicone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 6:   Filler' up with carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 7:   Clean up and add some weather stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 8:   Cut the bottom gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 9:   Build the pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 10:   Build the mat board air baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 11:   Bolt it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 12:   Wire up the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 13:   (Update!) Post filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 14:   Test it out! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Author:Zach    Zach Radding DesignsI run a small design consultancy specializing in custom electronic prototypes and one-off builds

Intro:  Build a laser cutter fume extractorI built my first laser cutter in 1996 and learned right away that laser cutters "stink". Well, at least the fumes from cutting smell awful and are quite harmful to breath. Aftertrying several fume extraction options, back in 2002 I found the ElectroCorp RSU filter. It was a bit expensive, I think I paid $1500, but it did a great job extracting eventhe worst fumes from cutting acrylic. Fast forward to 2013, I called up ElectroCorp to buy replacement filters for my unit and found out that the original company was soldand is now being run by another company. This new company claimed to supply the same replacement filters, but after almost three months of going back and forth withthem, it turns out that their filters are no longer the same, cost way more and look to be much less robust. Going through this challenging and frustrating process withthem got me thinking. After taking a close look at how my old unit worked, it was pretty clear that I could build a similar unit quite easily that would allow me to use off-the-shelf and readily available parts. I figured I would document the process so other people with laser cutters could try their hand at doing the same. Depending on thesupplies you have laying around your workshop, you should be able to build one of these for somewhere between $400 and $450. Here's how...

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 1: Gather major components and suppliesParts:

Qty (1) Fantech Inline Exhaust Fan, 392 CFM, Centrifugal for 6" DuctQty (1) 29500 Honeywell Air Cleaner Replacement FilterQty (2) 3M Filtrete Air Conditioner Filter, 15-Inch by 24-IncQty (1) Duck Brand 1285234 24-Inch by 15-Inch by 1/4-Inch Foam Air Conditioner FilterQty (1) 55lb bag of activated carbon (I called them and spoke to Karrie Gibbons. Just ask for "4 by 8 coconut shell carbon, for vapor filtration")Qty (1) Harbor Freight Router Speed ControlledQty (1) Roll of squishy neoprene shelving liner (It's about 1/8" thick, soft, makes great gaskets)Qty (4) 2inch castersQty (1) 3/8" Romex clamp or cord strain reliefQty (4) 3/8inch threaded rodsQty (8) 3/8inch nutsQty (4) 3/8inch wing nutsQty (8) 3/8inch washersQty (1) 5' roll of window screenQty (1) 5' roll of 1/4" wire clothQty (1) tube silicon caulkingQty (1) 3/8" dowel pin (for the router jig)An old extension cord (we only need the male end)4'x4' piece (half a sheet) of 3/4" thick birch plywood smooth on both sides.Mat boardWeather stripping (I had leftovers from other projects, but basically 1/4" thick, foam)Qty (1) Roll of post filter material (updated!)

Tools:

Plunge router with a straight plunge bitElectric staple gunDrill (with Phillips tip and 3/8" drill bit)Jig sawHot glue gunHearing protectionFace maskDust maskRubber gloves

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 2: Cutting disks and ringsI started out making a jig for my router. If you have a circle cutting jig you can obviously skip this step. We need to cut two inner and two outer rings plus the top andbottom plate (note that the bottom plate doesn't have the 6inch hole in the center). I used the jig saw to cut out the top and bottom plate.

Remember to wear all your safety gear!

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 3: Install the castersFigured it would be easiest to do this now. Just screw them to the base plate (the one without the hole).

Step 4: Staple the screen and mesh into placeiThe goal is to end up making two cylinders with the sets of inner and outer rings that are just a little taller than the hepa filter, which is 12" tall. I started by cutting strips ofthe 1/4" wire cloth 12" wide. I stapled this to the outside of the smaller inner rings and the inside of the larger outer rings so that the total height of each cylinder is 12-1/8". Then I lined the wire cloth with the fine window screen. I used a ton of staples since I wanted to be sure it didn't come apart and that there was no gaps between thewood and the mesh.

Step 5: Glue the mesh cylinders down to the base with siliconeI drew a circle on the bottom plate so I would know where to position the inner cylinder. Then I ran a bead of caulking around the circle and squished the cylinder intoplace. I did the same with the outer cylinder.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 6: Filler' up with carbonThe carbon comes in something like a potato sack. I recommend you leave it in the box it's shipped in as there is fine carbon dust that seeps through the bag. I just useda cup and filled up the space between the two meshes. It is a bit messy so I would do it outside on a surface that you don't mind spilling a little carbon.

Wearing a dust mask and gloves is a great idea for this step.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 7: Clean up and add some weather strippingClean all the carbon dust off of the top edges of the inner and outer rings. Vacuum out the center area. Apply weather stripping to both the inner and outer rings. I alsoadded some weather stripping to the underside of the top plate.

Step 8: Cut the bottom gasketI cut a circle out of the shelving liner that was approximately the same size as the outer diameter of the hepa filter. I then placed it in center area so the hepa filter wouldsit on top of it and no fumes would leak under it.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 9: Build the pre-filterTo save you from replacing your hepa filter as often, there is a pre-filter that filters the "big" particles. To make it, I cut a 11-3/4" x 25" piece of the 1/4" wire cloth androlled it into a cylinder overlapping the ends by about 2". Then I used some gaffers tape wrapped around the top and bottom edges to hold it together. I cut the 1/4" foamto fit inside the cylinder and both layers of the 3M Filtrete filters to fit on the outside of the cylinder. A piece of gaffers tape holds the 3M filters together.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 10: Build the mat board air baffleHaving a laser makes cutting cardboard a breeze, but you could probably do the same by hand. Take a look at the attached DXF file.The baffle needs to fit snugly insidethe pre-filter. It should be pretty easy to tell how it goes together. I used a fair bit of hot-glue to make sure there were no leaks. You might need to adjust the dimensions alittle if your pre-filter cylinder is slightly different dimensions.

File Downloads

baffle.dxf (41 KB)[NOTE: When saving, if you see .tmp as the file ext, rename it to 'baffle.dxf']

Step 11: Bolt it all togetherI cut the threaded rods to 15" and bolted everything together. You will want to tighten all the bolts evenly to compress the weather stripping straight down.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 12: Wire up the fanI cut the male end off an old extension cord and wired it into the fan's junction box. I used a Romex clamp to provide strain relief. Then I plugged the extension cord intothe variable speed router controller (which is just a high current rheostat). You could just add an on/off switch, but I like to be able to turn the fan down when cutting thinmaterial like paper, so that it doesn't get blown around.

Step 13: (Update!) Post filterMy old unit had this blue fuzzy filter on the outside of the carbon filter (see the picture at the beginning of this Instructible). I never could figure out why it was there sincethe carbon did such a good job removing the fumes. What could be left to filter out? Fortunately, Soundgod06 posted a comment asking if I saw carbon dust blow outwhen I turned on the filter. The answer was no, I didn't see any dust, but it got me thinking... Just because I couldn't see it, doesn't mean it wasn't there. Ah ha! THAT'Swhy the blue fuzzy filter was there. It's there to grab any carbon dust pushed out by the blower. It was simple enough to add, I just ordered a roll from McMaster for $19,cut it to fit in between the top and bottom plates and pressed it into place. I just overlapped the filter material at the end, and tucked the free end behind one of thethreaded rods. It holds there quite nicely.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

Step 14: Test it out!Plug it and flip the switch! It should draw quite nicely when on high. Hard to say what the final CFM rating would be, but it seems to be plenty to evacuate my laser.

There is no guarantee that this filter is filtering out 100% of the bad fumes, so use it at your own risk. So far, it has worked pretty well for me.

Related Instructables

SimpleSoldering FumeExtractor bybobyo134

How To Build aSolder FumeExtractor byKOMetzler

mypowerful fumeextractor(Photos) bygada888

Soldering ironholder withfume extractor(video) bylegwinskij

solder fumeextractor myway bygratefulfloyd4774

How to build aFume Extractoron the cheap bycatfang

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

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Comments

27 comments Add Comment

 bratan says:  Jan 23, 2015. 11:49 AM  REPLYVery very impressive! I'm going to make one after I get laser cutter. Thank you so much for instructions!

I'm curious have you considered an external enclosure for it? Maybe some kind metal with lots of holes rolled into a cylinder... :)

 wentzele says:  Jan 15, 2015. 6:40 PM  REPLYHow many times can you replace the carbon with a 55lb bag?

I am planning on building one of these. Great project, I live with neighbors close by and still plan to exhaust outside by adding another other container whichwould then duct outside.

 TonK1 says:  Dec 12, 2014. 12:05 PM  REPLYThis is awesome. I have been looking for a fume filtration for my laser, and this fits the bill perfectly. I definitely plan on making one. I do have a question.

How is the blower attached to the filtration system? Is it just set there? Or is there something securing it in place?

- Ton

 Zach says:  Dec 15, 2014. 3:10 PM  REPLYHi Ton - I cut the hole so that it would basically be a press fit. I've fixed the few minor leaks with silicone caulking. Guess that could also hold the blowerin place if your hole was a little large.

 TonK1 says:  Dec 17, 2014. 1:51 PM  REPLYPerfect. It seemed like it was just a pressure fit, but wanted to confirm. Out of curiosity, how far a run are you making with the hose? Are you using areducer when it reaches the laser cutter (unless you have a 6" exhaust on your laser). Also, did you use the entire 55 pound of charcoal in the unit?

I also have a small airbrushing booth, where I spray water based paint. I think I will make a manifold, so I can also extract fumes from there.

This is a great tutorial, cant wait to build it.

 bar2 says:  Dec 15, 2014. 2:45 PM  REPLYMade one and it works great!

You can use your laser cutter to make the top and bottom pieces if you split them into multiple sections. I've attached the .DXF file, they are intended to becut from 1/4 inch wood, then stacked two layers thick to make 1/2 inch. The top and bottom layers should be rotated or flipped so that the joints do not lineup.

Thanks for the project!

parts.DXF99 KB

 elincango says:  May 10, 2014. 6:17 AM  REPLYthanks. today start construction. good luck for me and amazing work friend Zach

 elincango says:  May 10, 2014. 6:08 AM  REPLYtanks

 soundgod06 says:  Jan 8, 2014. 7:15 AM  REPLYWith the carbon being the final step, what prevents the fine carbon dust from blowing all over your shop? Also I'm surprised you didn't pirate some parts off yourold extractor, namely the blower and speed control.

 Zach says:  Jan 8, 2014. 8:20 AM  REPLYHa! I had the same thought, which is why I turned it on the first time outside. I imagined a cloud of black dust, however, there just wasn't much dust at all.However, adding a final layer of filter mesh on the outside to catch any stray dust is probably not a bad idea. The original ElectroCorp had this.

 Zach says:  Jan 13, 2014. 2:37 PM  REPLYYou're original question about dust got me thinking about it... So, I just updated the instructible and my filter to include the final blue poly filter. Justlike the original unit. This should catch any seen or unseen carbon dust.

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

 soundgod06 says:  Jan 8, 2014. 9:15 AM  REPLYWhat about why you chose not to pirate parts off your old unit?

 Zach says:  Jan 8, 2014. 11:23 AM  REPLYI wanted to see if I could duplicate the performance of the older commercial unit with completely off the shelf items. I also might try my hand atmaking a custom sized HEPA for the old unit. Then I'll have TWO fully functional and serviceable filter units.

 chipkona says:  Jan 8, 2014. 12:28 PM  REPLYHow long does the carbon last.How do you know when to replace it?

 Zach says:  Jan 9, 2014. 1:10 PM  REPLYI wish I had a better answer, but this is a tough question. In the past, I replaced the carbon when I started to smell the slightest amount of burnt acrylicoutside the cutter. However, by the time you smell fumes, it's kind of too late.

 ryanstone143 says:  Jan 8, 2014. 7:09 AM  REPLYGreat work, really, but there are so many carbon filtered exhaust kits out there why spend the money or time to build this?The VenTech IF6CF620 is one (of many) example(s): http://www.amazon.com/VenTech-IF6CF620-Inline-Virgin-Charcoal/dp/B0052ZPMAG(The cost is $134.75 and it moves 440 CFM.)

 Zach says:  Jan 8, 2014. 8:16 AM  REPLYI actually looked at that unit, but concluded that there was nowhere near enough filtration with it to remove odors from cutting acrylic.

 ryanstone143 says:  Jan 9, 2014. 1:01 PM  REPLYI figured you probably had a good reason not to use a off-the-shelf product! (I'll keep a lookout for any HEPA based units you might be interested in.)

 Slim49 says:  Jan 9, 2014. 5:00 AM  REPLYImpressive

 ynze says:  Jan 8, 2014. 10:01 AM  REPLYVery useful! Thanks for sharing this.

Ynze

 primosanch says:  Jan 8, 2014. 7:04 AM  REPLYThis is a brilliant build. Thanks for sharing.

 MossdaleMakerspace says:  Jan 7, 2014. 8:28 PM  REPLYThis is an awesome build! If anyone out there doesn't want to go through the trouble of building one, you can check out hydroponics stores; they sell ductfans and carbon filter cylinders for pretty cheap. You can probably find one for cheaper than you could build one, unless you have a lot of the materialsalready laying around.

 Zach says:  Jan 8, 2014. 5:14 AM  REPLYThere are a ton of filtration options out there, but I knew the configuration used by my old ElectroCorp did the job of filtering acrylic fumes. I did a littlesearching in the hydroponics realm, but didn't find something that would allow me to do the same pre-filter->HEPA->activated carbon with similar surfacearea. If you know of a source that does, please post a link.

 broregret says:  Jan 8, 2014. 4:23 AM  REPLYIs the fan on the intake or exhaust side?

 Zach says:  Jan 8, 2014. 5:07 AM  REPLYThe fan is pulling air from the laser, pushing it through the pre-filter (in the center of the device), then through the HEPA, and finally through the activatedcarbon.

 Mayhem2 says:  Jan 8, 2014. 4:29 AM  REPLYNice practical sir!

http://www.instructables.com/id/Build-a-laser-cutter-fume-extractor/

 a.steidl says:  Jan 8, 2014. 2:50 AM  REPLYGood ible, thanks for sharing.