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Multi-Laser Setup

Some laser machines have multiple laser modules (e.g., a diode laser and a CO tube, or multiple diodes at different wavelengths). Rayforge supports multi-laser setups through tool selection and head configuration.

Overview

Multi-laser systems allow:

  • Multiple laser types: Combine different laser technologies on one machine
  • Different wavelengths: Blue diode for marking, IR for cutting
  • Varied power levels: Low-power engraving head + high-power cutting head
  • Specialized applications: UV for special materials, fiber for metals

Rayforge handles multi-laser machines through:

  • Laser head configuration: Define each laser's properties
  • Tool selection: Switch between lasers via G-code commands
  • Per-operation assignment: Choose which laser executes each operation

Common Multi-Laser Configurations

Diode + CO

Use case: Versatility - marking with diode, cutting with CO

Example setup: - Head 1 (T0): 10W blue diode laser - Engraving on metals, anodized aluminum - Low-power marking - Visible beam for alignment - Head 2 (T1): 40W CO laser tube - Cutting wood, acrylic, leather - Deep engraving - High power for thick materials

Advantages: - Best of both worlds - One machine for multiple materials - No tool changes required

Challenges: - Different focal lengths (may need Z adjustment) - Different power characteristics - More complex calibration

Dual Diodes

Use case: Different wavelengths or power levels

Example setup: - Head 1 (T0): 20W 450nm blue diode - General cutting and engraving - Wood, leather, cardboard - Head 2 (T1): 5W 1064nm infrared diode - Metal marking - Anodized aluminum engraving - Specialized materials

Advantages: - Similar focal characteristics - Easier mechanical alignment - Compatible power supplies

High Power + Low Power

Use case: Precision engraving and heavy cutting on one machine

Example setup: - Head 1 (T0): 5W diode for fine detail - Intricate engraving - Small text - Delicate work - Head 2 (T1): 80W CO for cutting - Thick material cutting - Fast production work - Heavy-duty operations

Configuring Laser Heads

Each laser head needs individual configuration in your machine profile.

Adding a Laser Head

  1. Open Preferences Machine Laser Heads
  2. Click "Add Head"
  3. Configure head properties (see below)
  4. Assign tool number
  5. Save profile

Laser Head Properties

Head Name: - Descriptive label for this laser - Examples: "Blue Diode 20W", "CO Tube", "IR Fiber Laser" - Helps identify which laser to use for each operation

Tool Number: - G-code tool identifier (T0, T1, T2, etc.) - T0 typically the default/primary laser - Must match your controller's tool configuration - Sequential numbering (0, 1, 2...)

Max Power (0-1000): - Maximum S value for this laser - Defines 100% power for this head - Typically 1000 for GRBL (S1000 = 100%) - See GRBL Settings \(30/\)31

Frame Power: - Low-power setting for framing (outline preview) - Should be barely visible, not cutting - Typical: 5-20 for diodes, 5-10 for CO - Set to 0 to disable framing for this head

Spot Size (mm): - Physical diameter of focused laser beam - X and Y dimensions (usually circular) - Affects fill patterns and kerf calculations - Measure by test cutting and comparing to design

Example Configuration

Diode + CO Setup:

Head 1 - Blue Diode: 

name: "20W Blue Diode"
tool_number: 0
max_power: 1000
frame_power: 20
spot_size_mm: [0.15, 0.15]

Head 2 - CO Tube: 

name: "50W CO Tube"
tool_number: 1
max_power: 1000
frame_power: 8
spot_size_mm: [0.08, 0.08]

Tool Selection in G-code

Rayforge automatically generates tool change commands when switching between laser heads.

Tool Change Command

G-code: 

T<number>      ; Select tool

Examples: 

T0             ; Select first laser (tool 0)
T1             ; Select second laser (tool 1)

Automatic Tool Selection

When you assign operations to different laser heads, Rayforge:

  1. Groups operations by tool number
  2. Inserts tool change commands between groups
  3. Optimizes order to minimize tool changes

Example workflow: 

; Job with diode engraving and CO cutting

T0                    ; Select diode laser
M3 S300               ; Diode on at 30%
G1 X10 Y10 F3000      ; Engrave logo
M5                    ; Diode off

T1                    ; Select CO laser
M3 S800               ; CO on at 80%
G1 X0 Y0 F500         ; Cut outline
M5                    ; CO off

Assigning Operations to Laser Heads

When creating operations, choose which laser should execute it.

In Operation Settings

Each operation has a "Laser Head" selector:

Choosing the right head:

For engraving text/logos (low power): - Use diode laser if available - Visible beam helps with alignment - Lower power for surface marking

For cutting thick materials: - Use CO if available - Higher power for deep cutting - Faster cutting speeds

For metal marking: - Use IR/fiber laser if available - Or diode for anodized aluminum - Specific wavelengths for different metals

Default Head Assignment

When adding operations: - Rayforge uses primary head (T0) by default - Change in operation settings if needed - Settings persist for similar operations

Controller Requirements

Not all controllers support multiple laser heads. Check your controller's capabilities.

GRBL Support

Standard GRBL (v1.1): - Limited multi-tool support - T0/T1 commands accepted but may not switch hardware - Requires custom firmware or external relay

Grbl_ESP32: - Better multi-tool support - Can control multiple PWM outputs - Configure via config.h

Custom GRBL builds: - May support tool changing via custom macros - Check your firmware documentation

Hardware Switching

Methods for physical tool selection:

1. PWM Output Switching: - Controller routes S command to different PWM pins - T0 PWM1, T1 PWM2 - Requires firmware support

2. External Relay: - G-code triggers relay (M3/M5 or custom M-code) - Relay switches power to different lasers - Works with standard GRBL

3. Manual Switching: - Software tracks active tool - User manually switches laser modules - Useful for testing or simple setups

Configuration Example (Grbl_ESP32)

In config.h:

#define SPINDLE_TYPE SpindleType::PWM
#define SPINDLE_OUTPUT_PIN GPIO_NUM_25   // Tool 0
#define SPINDLE2_OUTPUT_PIN GPIO_NUM_26  // Tool 1

Consult your controller documentation for specific configuration.

Calibration for Multi-Laser

Alignment

Different lasers may not be perfectly co-located:

Physical offset: - Measure distance between laser focal points - Account for X/Y offset in designs - Or use Rayforge's future "head offset" feature

Z-axis (focus) offset: - Different lasers may have different focal lengths - Adjust Z height when changing tools - Consider motorized Z-axis for automatic adjustment

Testing Alignment

  1. Create test pattern (crosshairs + small squares)
  2. Engrave with Tool 0 (first laser)
  3. Engrave same pattern with Tool 1 (second laser)
  4. Measure offset between patterns
  5. Adjust design placement or configure head offset

Power Calibration

Each laser needs individual power/speed testing:

  1. Run Material Test Grid for Tool 0
  2. Record optimal settings
  3. Run separate test grid for Tool 1
  4. Record settings
  5. Use appropriate settings for each laser in operations

Power levels are not interchangeable between lasers!

Example: - Diode at S300 (30%) for engraving - CO at S800 (80%) for same visual result - Different materials respond differently to each wavelength

Workflow Examples

Example 1: Logo Engraving + Part Cutting

Scenario: Engrave logo with diode, cut outline with CO

Steps: 1. Import design with logo and outline 2. Create raster operation for logo Assign to Tool 0 (diode) 3. Create contour operation for outline Assign to Tool 1 (CO) 4. Rayforge generates: 

T0                ; Select diode
; ... raster engraving commands
T1                ; Select CO
; ... contour cutting commands

Order: - Engrave first (while part secured to bed) - Cut second (part comes free)

Example 2: Multi-Material Job

Scenario: Mark anodized aluminum and cut acrylic in same job

Steps: 1. Design includes aluminum tags and acrylic frame 2. Engraving on aluminum Tool 0 (diode for anodized) 3. Cutting on acrylic Tool 1 (CO for cutting) 4. Position materials correctly on bed 5. Run job with automatic tool switching

Example 3: Detail + Production

Scenario: Fine engraving with low-power laser, heavy cutting with high-power laser

Steps: 1. Intricate design elements Tool 0 (5W for detail) 2. Structural cuts Tool 1 (80W for speed) 3. Same material, different laser strengths 4. Automatic switching based on operation requirements

Troubleshooting Multi-Laser Setups

Wrong laser activates

Symptoms: - T0 command triggers T1 laser - Both lasers fire simultaneously

Fix: - Check controller firmware tool support - Verify PWM output pin configuration - Test with manual T0/T1 commands - Check relay wiring if using external switching

Tool changes don't work

Symptoms: - T1 command ignored - No physical switching occurs

Fix: - Verify controller supports multi-tool (check firmware) - Check tool number assignments in head config - Test tool commands manually in console - May need firmware modification or external relay

Power levels incorrect after tool change

Symptoms: - S500 on Tool 1 gives different power than Tool 0

Fix: - Verify each laser's max power setting ($30) - Calibrate each laser separately - Ensure power values in operations match laser characteristics - Check \(30/\)31 haven't been changed

Alignment offset between lasers

Symptoms: - Tool 0 and Tool 1 engrave in different positions - Designs don't line up

Fix: - Run alignment test pattern - Measure X/Y offset - Account for offset in design placement - Consider adding head offset configuration (future feature)

Focus changes between tools

Symptoms: - Tool 1 is out of focus when Tool 0 was focused

Fix: - Different lasers may have different focal lengths - Manually adjust Z-axis when changing tools - Or install motorized Z-axis - Or add Z-offset in tool change macro

Advanced: Tool Change Macros

For advanced users with controller support, tool change macros can automate switching.

Example Macro (Grbl_ESP32)

Tool 0 Tool 1: 

; Macro for T1
G0 Z5               ; Raise Z-axis (clearance)
M5                  ; Ensure laser off
; Custom M-code to switch relay
M62 P1              ; Example: Enable relay for Tool 1
G0 Z0               ; Return to work height (Tool 1 focus)

Tool 1 Tool 0: 

; Macro for T0
G0 Z5
M5
M63 P1              ; Disable relay (back to Tool 0)
G0 Z2.5             ; Return to work height (Tool 0 focus, different focal length)

Check your controller documentation for macro support and syntax.

Future Enhancements

Rayforge may add in future versions:

  • Head offset configuration: Define X/Y offset between laser focal points
  • Auto Z-adjustment: Automatic Z movement for different focal lengths
  • Tool-specific speed limits: Different max speeds per laser
  • Visual tool indicators: Show which laser is active in simulation
  • Per-head kerf settings: Different kerf compensation for each laser