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Four-Motor Laser Spirograph

Four-Motor Laser Spirograph
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Bouncing a laser beam off a mirror rotating at any angle above 0 degrees will create the illusion of a circle to the human eye. Combine two rotating mirrors, and complex shapes begin to emerge. With every additional mirror, the perceived image becomes more complex and intricate, with the ability to create some very beautiful and bizarre flowing patterns of light.

Most laser spirographs consist of only two mirrors, limiting the complexity of their shapes for the sake of easy construction and bulky size. I have seen various guides on the net about three mirror spirographs, and after creating one figured I would up-the-ante: a four-motor spirograph in a compact box which is portable. This design will accept the use of any pen-style laser pointer, and through the use of potentiometers (variable resistors) to adjust the rotation speed of the mirrors, new shapes can be created. The benefit of using a laser beam allows the image to be projected to any size, on an indoor wall, an outdoor tree, through a lake/pool, snow, or the side of a building.

I hope you enjoy creating and sharing this display of light, which myself, friends, family, and strangers alike have been drawn to the limitless shapes created through exploiting human persistence-of-vision.

This is a rather complex mod. I'm already assuming you know how to solder, and have some basic understanding of wiring. Though you definitely could complete this mod as a first project, it will be rather confusing and challenging.




This violet projector made by user JoeMonkey from following this instructable -- Awesome job Joe!



***WARNING - SERIOUSLY, I MEAN IT, READ THIS ONE***
Laser light while very enjoyable can be extremely dangerous, dangerous to the point that most people don't understand the numbers of how powerful 10 mW (milliwatts) is, much less 100 or 500. While many projects have unnecessary warning labels, the concentrated energy from a laser beam really can blind the eyes of those who look into it's beam. Realistically, any laser with a power over 10mW (3.84mW is the power at which human eyes begin to be damaged) shone directly into a persons eye will de-nature (boil/cook) the rods on the back of their retina. This becomes a big problem if a person looks directly at the beam, as their center of vision will be damaged, inhibiting reading and other fine viewing permanently. The damage comes because the lens of the eye focuses light so precisely, what was 10 mW ends up becoming 80mW since it's focused on such a small area of the retina. It sucks to have your vision ruined for life for a toy. That being said, the cheap crappy red laser pointers for $2 tend to output about 0.5mW, and won't ever hurt you.

Second, don't shine a laser at anyone who doesn't want one pointed at them. In multiple states pointing a laser beam at a person is equivalent to assault with a knife. Many people have an irrational fear (thanks to being portrayed inaccurately in movies and television) that a laser beam is associated with a firearm, as such ignorant people fearing for their life can earn you a trip to jail. This includes pointing laser beams through people's windows, their car, or even simply near them, people are fearful.

Third, never point a laser beam at any aircraft or helicopter. These vehicles often use polycarbonate for their window "glass", and a laser beam anywhere on the window will scatter through the entire surface making it impossible to see out. Pilots take laser beams very seriously, and the government crackdown in the United States is especially strong. I personally know a friend who has been given a $1,000+ ticket and criminal record for pointing a 5mW laser at a police helicopter. Though the real life danger for pilots is minimal and over-hyped, government over-reaction to laser beams is not.

Fourth, eye damage from lasers usually happens without a victim immediately recognizing anything ever happened. A single flash from a 100mW might make you flinch and say, "Wow, that was lucky". In reality, you just toasted a line across your retina, but other parts of your eyes will compensate your vision to the point you don't notice. With multiple exposures (though really, a single 200mW+ exposure will truly screw you up), eventually the damage will accumulate, things become blurry, and you can't read.

Now with all the scary stuff out of the way, let's get to building!
 
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Step 1Parts Listing

Parts Listing
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Power Drill (~$80 )- Any power drill will do, we are only going through plastic.

Drill Bits (Set of 20 bits: $20) - 1/16", 1/4", 1/8", 3/8", 1/2" drill bits were used in this mod.

Electrical Conduit Box (~$3, Lowes) - Gray box measuring 6" Width x 6" Length x 4" Height. Most are intended as a junction box for pipes that carry electric wires, the one I purchased doesn't have any holes for pipes.

Electrical Conduit Fitting (Pipe Adapter) (~$1, Lowes) - My laser is exactly 3/4" at its front, as such I purchased a 3/4" -> 1/2" fitting. This allows the laser to be inserted into the box without wobbling around, but prevents the laser from falling into the box. Get whatever size fits your laser, only the beam needs to pass through.

Rotary Rasp ($5) - The proper method for drilling a hole for the conduit fitting would be either a hole-saw, or an omni-bit. As an omni-bit costs $50, and I couldn't be sure of the proper hole-saw size to use (each hole saw costs about $10), this cheaper method will do.

On / Off Toggle Switches 4x ($8) - $2 each at Radioshack. A ripoff sure, but they are convenient.

Red Safety On/Off Switch 1x ($4) - The red knob that you see on fighter-pilot joysticks and nuclear briefcases in movies. Complete overkill for this mod, but it just looks so cool!

1.5v-3.0v Hobby DC Motors 4x ($8) - $2 each at Radioshack. You could purchase mini-motors (cell-phone vibrators usually), which have the benefit of higher rpms at a smaller size (but they are usually to long to fit inside a box this small), but less torque and a whole lot of noise.

100 Ohm Linear Potentiometers 1/2 Watt 4x ($6) - These restrict the amount of electricity that can go into the motors, making them go faster or slower. Purchase them online, which automatically adds $4 of shipping. They are impossible to find at any brick and mortar store for low ohm ratings. Most stores sell very high ohmage ratings, such as 1k, 5k, 50k, 100k, 1M, while we want 100. The 1/2 watt rating is strongly suggested, but the motors would likely run anyways with 1/4 watt max. In this guide I initially used 500 Ohm resistors, which turned out to be far too stiff, then I dropped down to 120ohm, and now I suggest 100ohm. By being too resistive, I mean that while the knob in turning from full on to full off may be about 240 degrees of rotation, only about a 30 degree window will adjust the speed, making it really "touchy".  I purchased mine from Parts-Express.com

Potentiometer Knobs 4x ($6) - I purchased these knobs from Radioshack. They are decorative knobs, compared to the black and white-lined knobs. Either style works the same. They stick on the turning post of a potentiometer, and a tiny screw in the side tightens down onto the post.

1 Laser Pointer (~$10-$infinity) - For this guide I am using a 150mW Rayfoss laser, which cost $100. Most people can't justify spending so much cash on a light, here are your options.

Laser Companies
Rayfoss.com
- A respectable Chinese company, the first I recommend for newcomers. Rayfoss sells medium quality lasers for excellent prices. If you have any questions or concerns, e-mail them and expect amazing customer service. They bend over backwards to meet your order needs, and often throw in free goodies if you are friendly.

LEDShoppe.com- A non-respectable Chinese company, but they sell low quality lasers for rock-bottom prices. The quality is still far higher than what you would find at a normal store like Target or Sharper Image. Only purchase the 5mW from here, as their 20mw and up lasers all look the same brightness (they are all the same laser, but they do a POT mod on them to boost the power, resulting in higher amounts of infrared light which helps fake the numbers, green light stays the same).

Novalasers.com - A very respectable American company. Expect high quality for matching prices. They sell unusual lenses and diffractors.

Optotronics.com - Laboratory and military level equipment, ultra-high quality, very high prices. They are excessively overpriced on the low-end (below 100mW), but if you want very high-powered lasers, they are tough to beat.

Dragonlasers.com - Medium quality company. The main product to purchase from them is their laser safety goggles, which are top quality for low price. They have an excellent list of lenses and optics to purchase as well. As any respectable laser enthusiast would say, you should buy goggles since $25 is a small price to save your vision. I personally don't use them unless I'm working with something high powered (over 300mW), and am very careful and aware of what I am reflecting off of, that being said, I'm still only a 1/100th of a second reflection off my eye to go blind.

Wickedlasers.com - Stay away from this company. With good marketing they take advantage of unknowledgable newbies by selling them low quality lasers and gear for insane prices. Don't be sucked in by their flashy videos and photos (which are very misrepresented by playing with photoshop), they also boost their public image by paying people to write extremely favorable reviews of their company. To put it simply, they're a ripoff.

Soldering Iron 15 Watt ($15) - Radioshack, it heats up to about 260 C (500 F) to melt solder.

.022" Silver Rosin Core Solder ($3) - I prefer rosin core as it helps make cleaner welds with minimal effort. Again, available at Radioshack.

Needle-nose Pliers ($5) - Your second most important tool, next to the soldering iron.

18-22 AWG (Gauge) Wire ($3) - The raw wire used to conduct electricity between different parts of the spirograph. Any wire will work, but I find 18 AWG is the easiest to handle. Get a few different colors if you can, I use red, yellow, and black in this mod.

Electrical Tape ($2) - Used to wrap up exposed connections to prevent short-circuits.

Hot Glue Gun ($8) or BIC Lighter ($2) - To melt hot glue. After leaving my hot glue gun on for four hours straight, it exploded and blew the breaker. Now I use a BIC lighter.

Hot Glue Sticks ($4) - This glue will fix the motors in alignment for the laser beam, as well as hold on the external plastic laser mount and window.

Knife ($4) or Wire Strippers ($8) - To remove plastic sheathing from wires. I personally prefer the knife due to being able to remove sheathing which the strippers can't reach in tight spaces.

K'nex / Lego Lifters ($Peanuts) - Use anything 1cm (1/4") tall. These are just hard blocks that lift the mirrors up a bit to not scrape against the case.

2 AA Battery Pack & 9 volt Connector ($5) - Radioshack again, if you can, purchase the battery pack with the pre-attached 9 volt snap on connector. They were sold out so I had to use bare wires to attach my own 9-volt connector

Plexiglass/Acrylic Glass (Optional) ($10/ 2'x4' sheet") - A window for where the laser exits. It's not necessary in any way, and to some extent causes your laser to scatter upon passing through it. I just put on the window to help minimize dust on the mirrors.

1" Diameter Acrylic Mirrors ($5 / 24 mirrors) - I purchased these at the craft store Michaels. I personally chemical treated these mirrors to transform them into "front surface mirrors", meaning there is no protective acrylic layer over the reflective aluminum, but rather the metal is exposed (and extremely easy to scratch) for a perfect reflection.

Sidenote on chemical treating: Purchasing an equivalent front surface mirror would cost $7-20 per 1" mirror. I went to my local automotive store, purchased Aircraft Stripper (chemically designed to not attack aluminum, but requires you to use chemical resistant gloves and be careful when breathing around the spray [brain damage]), to remove the protective gray backing from the mirrors and expose the aluminum. Even with chemical resistant gloves, it would burn through them every 10 minutes or so. This is a rather advanced step that is not necessary, but is highly encouraged to prevent laser scatter and is beyond the scope of this instructable. Google is your friend if you are interested. Process went: Spray stripper on gray adhesive, wait 10mins, wash in hot tap water, rinse with de-ionized water, dry with soft paper towel via pressing (no scrubbing); spray stripper on brown adhesive residue, wait 4 minutes, wash/rinse/dry; spray stripper on remaining residue, wait 2 minutes, wash/rinse/dry, done.

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159 comments
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Apr 11, 2012. 9:32 PMmechanicalities says:
Hi! I'm doing this spirograph as an honors project for physics II. (Thanks for posting it, btw) Your instructions are written beautifully and I have learned a great deal about parts, tools, and methods while making this. My goal was to learn how to solder, which I have... but also a whole lot more!

Anyhow, my only stumbling block has been in placing the motor-mounted mirrors. Could there be an easier way to place them in the box other than hot glue? I find the need to adjust them as I work down the line and pulling them out gets messy and risks knocking off a mirror each time. My professor suggested that I use air dry clay (which helped with the slight z-axis angle from the cone shaped projection) but when it dried and I went to glue it permanently down... it moved out of the desired position.

I really knew nothing about any part of this kind of thing when I chose to do this. I had a drill, hot glue gun, and pliers when I started out, lol. :) This has been a fun and rewarding experience so far... I just want to play with it now! Do you have any suggestions for me? Should I trace around the bottoms of the motors in the box to help line them up? Maybe there is a defined angle arrangement that always works? Will they automatically line up if I'm playing "Dark side of the moon"? (wouldn't that be cool?) I usually miss the most obvious things... thank you so much for any kind of input you have!
Apr 12, 2012. 10:57 AMmechanicalities says:
I looked at those case fans and they look like they will greatly ease my troubles. I like having something solid to glue the mirrors to and a shiv sounds much nicer than my inexperienced eyeballing ability. You are a genius! I'm ordering them today. Also, I'm using 100ohm 2W pots for this... will I need to add a resistor or something since the fans are 12V? Might it limit my shapes or shake off my mirrors if I don't?

I hadn't thought to put the box in the freezer either, so thank you for that tip. I have quite a bit of glue residue that I can now eliminate. :) I look forward to trying your 108 degree ring out too. I think my conduit box is larger than the one you used, so I might have the room to have it work. It will be way more easy to mark the fan placement than it was ompared to my lumps of air dried clay.

I'm really glad that I asked here about this... you've made my day! Thanks again for your help.
Apr 23, 2012. 8:19 AMmechanicalities says:
I DID IT! It's done. Thank you so much for your input, again. I needed to keep thinking it through and your response encouraged me to do so. :)



I didn't have time for the case fans to come in from China before I needed to turn in my project, so I had to improvise. I took some wick tabs from the bottom of cheap votive candles and soldered them to the tip of the motor. That gave me a solid surface to glue the mirrors on to. Also, the tabs are somewhat flexible and I could adjust the tilt after putting them on. That enabled me to use Lego's as the motor stands, since my tilt wasn't so large.



I'm really excited about this working, it is the most intricate project I've ever made and EVERYBODY loves playing with it! I have to let my teacher keep this one and I've already started my second one (for me to keep). I'm trying your 108 degree model and it really seems to be working great. You have made the the envy of my pre-engineering classmates, lol. I'm already enrolled in the fall electronics engineering program, after enjoying this project so much. Thanks for the help and the inspiration, man! :)
Jul 28, 2011. 11:55 AMElectorials says:
Really awesome!

I made this one, and it works perfectly!
It makes some really nice pictures, like rotating 3D shapes :)

The only problem is that the hot glue doesn't hold the mirrors when they're rotating really fast.

Great project!

Thanks
Aug 3, 2011. 12:57 PMElectorials says:
I made the spirograph just like your instructable, only the lay-out is different.
It seems to work really great now! the glue isn't a problem anymore ;)

Thanks for the instructable!

Apr 20, 2012. 7:12 PMsSkEzAfNs says:
i found the area around 2:30 to be particularly awesome.
Aug 8, 2011. 1:00 AMElectorials says:
Hello,

What do you mean with "laser building ranks"?

And I'll let youknow when I make something new ;)


Greetings,

Electorials
Mar 10, 2012. 3:41 PMJUSTCOCONUTS says:
Just got mine done and posted it today!
http://www.instructables.com/id/4-Motor-100mw-532nm-Laser-Spirograph-Budget-Build-/


Thanks for sharing your's with us!!!!! It was the push I needed to get one built.


Jan 24, 2012. 6:17 PMlsutigertuff says:
I think I've been hit by the laser bug and hard at that. Over the past 3 weeks I've been preoccupied with all aspects of the working laser...Ive purchased The Arctic 3 by Wicked Lasers and several turnkey laser projectors and scanners by American DJ. With that being said It's no surprise that I must build one one now. This project is great and just what I was looking for as a my standard for this first attempt. Please, I'm open for any and all suggestions that may help me actually achieve this
Thank you and look forward to being a part of this forum.
Jan 14, 2012. 1:55 PMelizabeth kennett says:
Regarding how to adjust the wobble: do a google search on "harmonograph" and see if that gives any helpful pointers.
Jan 11, 2012. 11:37 AMjackattack155 says:
would this instructable work with a dollar store laser pointer? very cool project and i am considering builing one of my own, thanks!
Jan 6, 2012. 8:53 AMDELETED_nepawoods says:
(removed by author or community request)
Jan 6, 2012. 5:48 PMDELETED_nepawoods says:
(removed by author or community request)
Jan 3, 2012. 11:07 AMelizabeth kennett says:
Regarding your excellent safety warning: Some years ago (15? 20? more?) I very foolishly decided to look inside the laser checkout window at the grocery store checkout and get a closer look at that pretty red laser. It was the briefest flash I could manage and within the first half-second afterwards I realized "That was really stupid." The blackout spot in the middle of my eye was, fortunately, just a small spot that eventually healed, but it took over a decade.

ALL PERSONS DEALING WITH LASERS IN THIS OR ANY OTHER INSTRUCTABLE SHOULD TAKE THIS WARNING WITH THE UTMOST SERIOUSNESS!!!
Dec 27, 2011. 11:07 PMStandard2 says:
Could I get away with using glass mirrors instead of acrylic?
Dec 28, 2011. 10:59 AMStandard2 says:
Do you mean I should put more weight on the opposite end of the motor?
Dec 10, 2011. 10:49 PMRevonok says:
Followed your design and it came out amazing! Thanks for the great guide.

Dec 6, 2011. 4:04 PMjack_of_all_everything says:
im looking into building an 8 mirror RGB verson of this. i tracked down affordable front surface mirrors in the form of #3 dental mirrors (20mm). they come in a pack of 12 for roughly $20 on the good ole flebay. just gotta remove them from their holder/backing without breaking them. ill be using a 200mw green, 500mw red and 400mw UV in this.
Nov 18, 2011. 11:19 PMsitten_duck says:
Do you have to keep turning the knobs to get all the variation in the patterns, or does the variation occur naturally as the spirograph is allowed to run?
Nov 20, 2011. 10:26 AMsitten_duck says:
Awesome, thank you for your reply. I'm planning on building one based off of your design. I thought about adding an additional mirror at the end, but instead of attaching it to a motor, attaching the mirror to some type of membrane that's been pulled tight across an opening in the box opposite the projection window. When set next to a speaker, (I'm hoping) the sound waves would cause the membrane to move back and forth causing the projection to shrink and expand, pulsating with the music (or at the very least have some type of interesting response). Do you think it might work?
Nov 14, 2011. 3:51 PMmonishgogri says:
Can I make the same with a CD / DVD Drive Laser diode?
Thanks in advance, :)
Nov 14, 2011. 10:59 PMmonishgogri says:
Thanks a ton ;)
Nov 14, 2011. 2:59 AMbuilding_boy says:
couldn't you use a spade bit?
Oct 27, 2011. 3:11 AMcurlyfry562 says:
Dan, thanks for the great instructable. I finally finished mine here are the results

http://www.instructables.com/id/Laser-Spirograph-Using-arduino/
Oct 16, 2011. 2:40 PMfnamen says:
Excellent general and specific instructions. Especially the intro was most useful.
Oct 10, 2011. 9:37 PMananda1 says:
how many mw can you go before viewing the projected laser show (on a wall) will hurt you??? thnx
Jul 14, 2011. 4:01 PMagr00m says:
Either they raised the price of the pots you used or they don't sell them anymore. I see the only 100 ohm at partsexpress is now $4. Did some digging around at about 8 other component sites and it seems all 100's are $4 and up, yet the Kohm ones are easily $2 and less, some down to $.50. Any idea why or where I can get some cheap ones? It would be nice to spend ~$8 rather than $20 on them.
Sep 5, 2011. 9:31 AMJuxe says:
I think you could put a 100 ohm resistor in parallel with any potentiometer to make the total resistance a range of 0 to 100 ohms. Any resistors in parallel will never exceed the resistance of the lowest value resistor. The range might not be as linear, I'm not quite sure about that part; some math would let you know, though.
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Author:QuackMasterDan
I have a passion for tweaking things. Whether it be modding video game consoles, creating custom laser displays, or any creations with lights I love solving problems through unorthodox means. I like ...
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