Laser Beam Alignment for Flying Optics Machines

Tools & Materials

Before You Begin

Alignment assumes:

• Laser tube fires normally
• Coolant is flowing
• Mirrors are clean
• Nothing inside the machine is loose

Only use short pulse bursts.

Keep all covers closed during firing.

Alignment must be done in order.

Mirrors are named:

• Mirror 1 — closest to the tube
• Mirror 2 — gantry mirror
• Mirror 3 — head mirror above the nozzle

Phase 1 — Tube → Mirror 1 Check

Before adjusting anything, confirm the beam is entering mirror 1.

Open the rear compartment and visually inspect:

• Tube points directly at mirror 1
• No obstructions
• Path looks centered

If the beam misses mirror 1 entirely, correct tube positioning first. Alignment cannot begin until the beam hits the first mirror.

Phase 2 — Mirror 1 → Mirror 2 Alignment

This aligns the beam along the Y-axis travel.

Step 1 — Create a Target

Layer masking tape into a thick pad (10–15 layers).
Place the target on the bracket of mirror 2.

The tape must not touch the mirror surface.

Step 2 — Rear Position Test

Move the gantry to the rear of the machine.

Close the lid and fire a short pulse.

You should see a dark oval burn.

Mark the edges of the burn with a pen.

Step 3 — Front Position Test

Move the gantry to the front.

Cover the target with fresh tape.

Pulse again.

Compare the new burn to the original.

Step 4 — Adjust Mirror 1

If the two burns do not overlap:

Adjust mirror 1 screws slightly.

Use very small turns.

Even 1/16 turn can be enough.

Repeat rear → front testing until the burns land in the same spot.

Goal: identical burn location regardless of gantry position.

When the marks overlap, mirror 1 is aligned.

Phase 3 — Mirror 2 → Mirror 3 Alignment

This aligns the beam along the X-axis.

Step 1 — Move Target

Place a layered tape target on mirror 3.

Step 2 — Left Position Test

Move the head fully left.

Pulse once.

Mark the burn.

Step 3 — Right Position Test

Move the head fully right.

Cover with fresh tape and pulse again.

Step 4 — Adjust Mirror 2

Use mirror 2 screws.

Repeat left/right testing until the burns overlap.

When both positions match, mirror 2 is aligned.

Phase 4 — Centering the Beam Into the Head

Place a 3-layer tape target over the entry hole of the head.

Trace the circular opening with a pen.

Move the head to the center of the table.

Pulse once.

The burn should be:

• centered in the circle
• slightly above center (normal)

If off-center:

Make fine adjustments to mirror 2 and mirror 3.

Repeat until centered and consistent.

Phase 5 — Final Spot Check at the Table

Place tape flat on the work bed.

Lower the table slightly out of focus.

Pulse once.

You should see:

• a clean round spot
  
• smooth edges
  
• no crescent or clipping shape

If the spot looks distorted, the beam may be hitting the nozzle and requires minor adjustment.

Alignment Complete

Alignment is finished when:

• rear/front burns match
  
• left/right burns match
  
• head entry is centered
  
• final table spot is round

At this point the beam path is straight and consistent.

Quick Troubleshooting Guide