$15 DIY Adjustable Line Laser Alignment Tool .

I am a maker and oftenly need accurate alignment of parts to join them and assemble properly.

I checked out a product named Laser Aligner on Bosch's website for a price of $150 to $500.

It's too much for a maker to buy this type of thing.(comparatively higher cost than Ender-3 3D printer- costs $250).

So,I decided to make my own DIY Laser Alignment tool Using Laser Diod and other Electronics. Also, This design fits on a tripod to make it steady while Aligning Procedure.

I make a 3 sider laserline emitter .

The main advantage of my design is that it contains movable sides which enable more flexibility for use.

Let's take a look at my build.

Let’s start by collecting supplies.

Warning: The project contains LASER.

Do not point laser directly or Indirectly into EYEs.

Step 1: Laser Dot to Laser Line Converter(Simulation)

Laser diod Emmit Dot Laser .But we need a line of laser for alignment of Material on Laser engraving Bed.
For conversion in Line laser, we use internal optical reflection inside glass Rod. Dot line passes through Cylindrical rod and it converts into line laser by the law of internal reflection.
For testing and Simulation of Light through a glass cylinder,I use a Light simulator for testing purposes.
Check out the link below for the Light simulator and create your own Line laser as per your need.

https://ricktu288.github.io/ray-optics/simulator/

In the simulator, a Light source is a beam light and uses a circular glass medium for internal reflection and gives the result in a Linear line on the wall.

Step 2: Testing Our Simulation in the Real World.

I Purchase a Glass sterile rod from amazon to use as an internal reflection cylinder.
Also purchased a 5mw power Laser from amazon. I cut a glass rod into 20mm pieces and connected a laser diode with a 5v 0.2mw power adapter to start the Laser.
I Just move the Laser diode at the tangent of the glass rod's Cylindrical surface and the Laser line appar on the Wall because of the Internal reflection of the cylindrical surface.
Now we need to make a holder for the Laser and Glass rod to make the proper mechanism.

Step 3: Design in Fusion360

I design a Laser Holder to hold the laser and Glass rod properly Horizontal and vertical for Proper alignment.
I take measurements of laser and Sterile rods and draw sketches on Fusion360.
The diameter of the laser is 6mm and the diameter of the sterile rod is 7.2mm.
First, draw circles for the laser.
2 lasers for a single plane.1 is for horizontal and 2nd is for vertical.
Check out the design and also make your own design from your ideas and thoughts.
We design 1 central module and 2 side modules to hold our laser and Rod for the project laser line.
Also, the side will be switchable as needed.
After the design, we need a.STL file for the 3D print our part.
Export file in.STL file.
Use slicer Software like CURA to make a . Gcode file for 3D print.

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Laser line module 3 v2.f3d
Download View in 3D

Step 4: 3D Print Parameter and Post Process

I have a Creality Ender-3 3D Printer to print my part.

Please use the below Parameter for Good print.

Material:PLA

Layer thickness: 0.2mm

Wall Count: 2 or 3

Infill: 20%

Built Plate adhesion: Skirt

Support: ON

Use Plier for Remove Support from 3D Print.

Also, use some Sandpaper for a better finish.

Step 5: Assemble Parts

After 3d Print, we need to Assemble the Laser, Glass rod,3d print parts in one product.
First Solder all six laser ends. Red Wire with red and Blue to Blue.
Connect Adapter with Laser wire as per Polarity.
Place all 6 Lasers into a 6mm hole in 3d print parts.
Break the Sterile rod into 20mm parts to fit inside tangentially in the 3d print part relative to Laser.
Connect all 3d parts with Nut & Bolt for rigidity.

Step 6: Testing

After assembling all parts, it's time to test our project.
After connecting the power source (Adopter), place our project on Tripod and start Switch.
It Shows Laser Lines on 3 of the side of the wall by side and inline.
Also, our project has the flexibility to rotate 2 of the sides at one and Project 3 Line in one wall to extend the Laser line.

Step 7: Uses of Laser Line Aligner.

The main use of my product is to Project lines on Walls and other Surfaces to marking for making straight lines and perfect 90* angle for better leveling of Furniture, Hangers, and other construction.

Other uses of Laser Line Alignment.