The Custom Enclosure Build for our Laser
The new FoxAlien 404XE laser CNC machine has brought new responsibilities, one of which is ensuring that the house doesn’t fill with smoke during each laser project. As tempting as it was to start using the laser right away, we knew we had to begin a custom enclosure build.
Why Build? Why Not Buy?
The decision to build a custom enclosure was made after weighing the costs, size, material, and customization requirements, which were better met by building rather than buying. I also had a lot of leftover wood from the workshop that could be put to use on this project.
Laser Custom Enclosure Build – Design/Build Requirements
I started with a list of requirements for the custom laser enclosure, including:
- Sufficient size for different laser/router attachments
- Removable front screen for switching between laser and CNC projects
- Removable ventilation system for laser projects that can be changed to a vacuum for CNC projects
- Portability (the enclosure must be easily moved inside during winter and outside in spring/summer)
- Multiple large viewing areas
- Room for the vacuum/vent system, air assist unit, LED controllers, and laptop on top
- Durable and attractive with LED lights
- Matte black finish
With so many needs and wants, it was not going to be an easy build. But we got planning the dimensions and double-checked both areas it will be living in, just to make sure the fit would be good.
Here are our very first drawings/measurements:
Laser Custom Enclosure Build – Plans
When we knew the sizes of the inside of the enclosure, as well as the sizes of the laser shielding and side wall acrylic screens, we could then concentrate on building the frame.
Our initial drawings had the venting/vacuum system, as well as the controller wires, coming out of the back wall. At this point, we also had the small tubing of the air-assist and the laser power cord coming out of the side of the enclosure (see images above). The top of the unit would be an extra viewing area fitted with a clear acrylic screen.
Upon further assessment and research, we changed things up a bit by moving the vacuum/vent system to the top. As smoke rises up from the laser, we thought it better to place the 4″ tubing directly above it, but we did keep the controller power cord coming out from the back.
We also kept the location of the air-assist tube and the laser wires, which would be coming out from near the top of the left side. This would mean that we still have three sides with a viewing window, and the top of our enclosure would be solid wood.
For 90% of the build, we used up most of our remaining 4″x6’/8′ lightweight pine boards. The top was made from a scrap sheet of 3/4″ 4’x8′ sanded plywood for added durability.
The enclosure was then sanded and painted matte black, and the front and side screens were added using magnets for easy removal.
With the plans and the materials all ready to go, we started to build the frame:
Laser Custom Enclosure Build – Let’s do it!
We recycled some scrap paneling for the back of the enclosure rather than use another piece of the 3/4″ plywood, which would add much less weight to the unit. At first, the door was going to hinge from the 3/4″ ply at the top, but then we changed our minds because we didn’t want it slamming down every time we opened it, and we couldn’t be bothered to find and install a damper or piston. So, the hinge was then attached to the bottom at the front.
With the frame complete, as well as all the access holes drilled, we then sanded and painted the enclosure in a matte black paint from Lowe’s. Then the front and side screens were added using magnets to make them easy to remove, and a door handle to complete the build:
The pictures don’t do it justice, but it looks pretty cool in person! The venting system was installed without an issue, so all that was left now was to add some cool-looking LEDs:
The pictures don’t do it justice, but it looks pretty cool in-person! The venting system was installed without an issue, so all that was left now was to add some cool looking LEDs:
Future Updates & Feedback
Pretty cool! Now we are ready to start our first projects with the new laser. We will make sure to come back with updates after a few uses to let you know how it is working and if we changed anything.
We would love your feedback/comments on our custom enclosure build. Let us know what you think.
