ZelosLaser Cutter 2.0 : Open Source, Sturdy & Versatile

by zelos113, published

ZelosLaser Cutter 2.0 : Open Source, Sturdy & Versatile by zelos113 May 1, 2015
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The Open Source ZelosLaser Cutter V2 is a full working unit to engrave and even cut material like plastics, wood, leather and much more. It is easy to build and has a number of exclusive features that cannot be found on other engraver machines.

If you build one, please share a picture! :)

Lets Engrave : ZelosDynamics Logo on Plywood

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ZelosLaser is the world’s first, high stable and completely open-source laser cutter and engraver. It has been designed to be sturdy, affordable and versatile. As open-source technology, we are also offering a number of documentation online for its design and implementation. Easy to build in under 4-5 Hours!

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BOM - bill of materials

Qty Part Name
5x Aluminium profile 20x20 Type B 15cm
4x Aluminium profile 20x20 Type B 30cm
4x Aluminium profile 20x20 Type B 40cm
8x Screws M2.5x15 (Wood version
13x -M3 Allen SCREW M3x10
6x -M3 Allen SCREW M3x16
12x -M3 Allen SCREW M3x20
5x -M3 Allen SCREW M3x25
89x -M4 Allen SCREW M4x8
14x -M4 Allen SCREW M4x20
89x washers M4 wide Brim
24x nuts M3 Normal
8x M3 lock nut
20x M4 Normal Nut
96x M4 threaded plate M4

1x GT2 Timing Belt 57CM
2x GT2 Timing Belt 87CM
2x GT2 Timing Belt 158mm Closed Loop
3x Timing Pulley GT2 20 teeth, 5mm Bore
4x Timing Pulley GT2 20 teeth, 8mm Bore
1x Steel Rod 8mm diameter 29,5cm
2x Steel Rod 8mm diameter 29CM
2x Steel Rod 8mm diameter 42CM
6x LM8UU linear bearings
3x 608z bearings
1x MDF Wood Base Plate 28x32 / 7mm thin
1x Laser protective glasses
3x Nema 17 stepper motor 36oz
1x Arduino Uno R3 or clone
1x GRBL-Shield
2x Pololu a4988 Stepper Driver
1x Power Supply 12V / 4A
2x 12V fan 4x4cm
2x Power Switch
1x Laser protective glasses
1x Laser Module 445nm 2watt M140 diode Copper Modules With Leads & Three Element Glass Lens
1x Laser Driver 3A 450nm TTL
4x Endstops
2x handholds
1x Various cable, different plugs ...

Tools you need
Allen Key M4
plier screwdriver
a brush or something similar
Metalsaw when the steel rods or aluminum profiles are not even cut when you buy it.
Jigsaw when the base plate has not been cut when buying

some wood glue (to glue a thin layer of cork on the bottom plate)

Begin with the aluminum profiles. screwed all together like in the Images.
Do not forget to push enogh M4 threaded plates into the V-slot of the profile.

glue the cork to the bottom plate as in the photos.
use a brush or similar to remove all the small blisters.

Turn around the bottom plate and put some weight on it.

Wait until the glue is dry.

Attach the handholds and Baseplate to the Frame
Attach the handholds with 4x - M4x20 screws.
Attach the Base Plate with the printed Holders.

Prepare the axis
Sliding/push the LM8UU linear bearings on the Steel Rods.
Attach the steel rods to the chassis.
fix the carriage to the linear bearings with cable ties.


Wiring Diagram for 2watt Laser
For the wiring we use a very reinforced system.
it is very easy to build and works great.

-If you want to use two motors with two Stepper Driver for Y axis, you can "clone" any axis for use two motors and two drivers for a single axis. The CNC shield is capable of it
Check this for more CNC shield infos.

Don´t connect the laser before adjust the power on the laser driver.

Before you can start you need the Arduino IDE, available on their webpage.
Arduino IDE http://www.arduino.cc/en/main/Software

Modified firmware for the Arduino UNO R3 or similar clone:

(Modified for Version 2.0 ZelosLaser Cutter with 2 Axis)

Grbl wiki: github.com/grbl/grbl/wiki

drawing software: Inkscape 0.91/combined with a laser engraver plug-in.
( we use @now the one Plugin from the Microsclice Engraver. We are working on our own plugin)

Grbl needs G-Code.

We need another Program to send the G-Code to the Arduino UNO R3 board.

Grbl Controller 3.0 by Zapmaker http://zapmaker.org/projects/grbl-controller-3-0/


NOTE: Before starting, make sure that any older installation of Grbl has been completely removed from the Arduino IDE.

Download the Modified Grbl source code (v0.9i)

Once downloaded, unzip it and you'll have a folder called grbl-master or something similar.

Make sure you are using the most recent version of the Arduino IDE (last tested on v1.61).

Load Grbl into the Arduino IDE as a Library.

Launch the Arduino IDE.  
Click the Sketch drop-down menu, navigate to Include Library, and click Add .ZIP Library, note that this still works with a folder (prior to IDE version 1.6.2 this will be Import Library..., and click Add Library...).  

Select the Grbl folder inside the grbl-master folder when asked to select a library folder you'd like to add. The correct folder only contains the source files and an example directory.It may take a few seconds for the Arduino IDE to import it.  

NOTE: For pre-v1.05 Arduino IDE users, you will need to manually add Grbl into your Arduino libraries, so that it will appear in the Import Library... menu. Search the internet for how to install, then skip to step 4.

Open the GrblUpload Arduino example.  
Click the File down-down menu, navigate to Examples->Grbl, and select GrblUpload.  
Compile and upload Grbl to your Arduino.  
Connect your Arduino Uno to your computer.  
Make sure your board is set to the Arduino Uno in the Tool->Board menu and the serial port is selected correctly in Tool->Serial Port.  

Click the Upload, and Grbl should compile and flash to your Arduino! (Flashing with a programmer also works by using the Upload Using Programmer menu command.)  

Once you have your Grbl library set up in the Arduino IDE, you can update, replace, or modify the Grbl source code in the library folder. On a Mac, it's located in ~/Documents/Arduino/libraries/. On Windows, it's in My Documents\Arduino\libraries.

You may need to restart the Arduino IDE for this change to take effect.

No fuss! No muss!


I hope you guys like the tutorial.
many greetings,

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Подскажите пожалуйста. Нашел вот такие двигатели Nema 17 34mm 12V 26Ncm(36.8oz.in) 42SHD0001. Но они есть на ток 0,4А и 1,5А. Какие лучше сюда установить?

the link Grbl Controller 3.0 by Zapmaker http://zapmaker.org/projects/grbl-controller-3-0/

has been dead for a long while can you provide alternative path ..

have you tried to cut even pcb?

4k to 10k standard resistor

Hi! What is volume of resistor in TTL?

BOM - bill of materials has been updated!
Wiring Diagram added.

All 3D printed Part files has been updated to version 2.0

GRBL0.9i_Library_zelosLaserengraverV2.zip has been added to the Instructions. GREAT to see another build from another person :)

Jul 24, 2015 - Modified Jul 24, 2015

modified GRBL library for the Arduino IDE will be available very soon.
almost a complete update of the Printed Parts.
2 . Generation is ready to come out ;)

I have complety build ,but I have problems which software and firmware you use and how Laser driver you use.
Can you send me some links ?


Hi dear friend,
Can you upload your complete config arduino ?

Thx :)

Please never forget that the laser can cause serious damage to your eyes. always wear safety glasses!!! Avoid to look directly into the beam.

are you relying on goggles for eye protection?

Take a look: http://3dprintzothar.blogspot.com/2014/08/40-watt-chinese-co2-laser-upgrade-with.html

i hope this will help. there is all what you need. plugins,firmware,BOM and more.

I'm trying to build a CNC Laser Machine and I want to use CO2 laser to cutter acrilic, wood and metal sheets.
I want to know if can I use arduino to control the CO2 lasers? My CO2 laser cutter may be like yours.
Thank you.

currently we are working on the Electronics Case Design.
keep looking from time to time ;)

that would work but you need a different firmware version of GRBL and a different wiring for the Mega2650 Board!

Where can i find that?


If any have problems with getting/pay for the aluminium profiles, then take a look at these http://www.thingiverse.com/thing:800597. I have used them in other projekts and they are ouite stable.

Printable Extrusion Kit

Hey vandborg!

What have you used them for? I am really interested to see people using it the extrusion.


What do you mean?
"2x - handles"

May 9, 2015 - Modified May 9, 2015

If you are interested in high-quality and low-cost aluminum profiles, I recommend this seller. Cut exactly to the mm.

The total price of a kit is about 350 €. (High Quality/high precision)

depending on which material you use to print the parts, what quality of screws etc

have a nice day

Hey Coffemaster,

Of course I'm going to upload the wiring diagram. I just need to find time to do it: P

The Pololu a4988 Stepper Driver can you find too on Aliexpress from the same seller as your Motors:http://www.aliexpress.com/store/product/10pcs-lot-Reprap-Stepper-Driver-A4988-stepper-motor-driver-10pcs-heat-sink-with-sticker-free-shipping/1494743_32230923668.html

The Motors will works without problems.

If you have any further questions, you can ask me. no problem. I'm happy to help.

have a nice day

Thank´s for your fast reply. Do you have no idea the total cost of this project?

And how much will it cost and where can i find the Aluminium profiles 20x20 Type B?

Hey Coffemaster,
very soon we will start our Kickstarter campaign. There you can buy a early bird complete kit.
but if you're searching just about the GRBL Shield, here:http://www.aliexpress.com/item/3D-Printer-CNC-Shield-for-Arduino-GRBL-Compatible/1931530630.html
have a nice day

May 7, 2015 - Modified May 7, 2015
Coffemaster - in reply to zelos113

Thank´s for very fast reply. Will you upload a wiring diagram so i know how to wire everything? Where can i find the "Pololu a4988 Stepper Driver" And Will this stepper motor work? http://bit.ly/1H3PyPB Sorry for so much questions...

Comments deleted.

Where can i buy a GRBL-Shield?

It is me a pleasure :)
you are welcome

Thank you, already placed order :)

May 1, 2015 - Modified May 1, 2015

hey james_III,
This Project is still in process but i do my best.

for now i use this:http://www.aliexpress.com/store/product/300mw-purple-Laser-Module-mini-Laser-engraving-machine-laser-cnc-parts/922826_1976917790.html

Wavelength: 405nm (purple laser)
Optical power: real 300 mW

I use it at 250mw over a year and the diode still working fine.

but i try to upgrade it to a 2 watt M140 Laser Diode with a big driver.

i will add a LCD with SD card support to the Version 2.0
Thanks for your comment.

have a nice day

Can you be more specific about 250mw laser module
Where to get one?
What power driver?
Lenses? or is this really ready module?
Lastly how long this 250mW laser module last before new is needed?
I suggest to use some sort of display and SD card module, so there is no need for computer.