K40 Laser Pointer Beam Combiner

thingiverse

Inspired by many other designs, but simplified as much as possible. This was designed around low cost, making use of the smaller 20mm x 2.1mm mirror and a 6.5mm laser diode. Press the laser in before mounting it, but leave the mirror out to save yourself some headache. The base is made large enough to give you at least two fasteners to work with when mounting it to the housing. I found on my K40 the laser is nowhere near the center of the hole, and without completely tearing it down and physically moving the mirror mounts there was no way it ever will be. Thus, a big base with 4 slots. Just needs to be mounted solid enough to not move on you, so two screws will secure it and keep it in place. I'm planning to line it up by eye, after carefully burning a spot on some masking tape as a guide. Keep a fire extinguisher handy - it's going to be pretty out of focus and will make a lot of heat. Best to go at that in short bursts. Once close enough by centering the spot, mark and drill your holes where you feel you'll get the best ease of adjustment. The rest should be (in theory) pretty simple. Drop the mirror in place, pop on the clip to retain it, and tweak the alignment so your burn spot on the work is in the same spot as your pointer. Please note this is a thing in progress. I have not yet printed this, but will in the next couple days. If you happen to print it before I do (and there's no guarantees everything is perfect), please let me know how it worked for you.