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Old 08-17-2013, 04:52 AM #1
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Default Machined a New Button for my Pen Laser

This past week, there have been several company representatives come and do product demos and presentations and my managers do trainings and presentations and would you know it, they all brought the ubiquitous red laser pointers for their use but quickly ran out of batteries in the middle of the presentation.

As luck would have it, there's a laserist in the audience. I let them use my 450nm blue pen laser and by the end of the week, the button was worn out and mangled. The cheap rubber from my china pen host wasn't up to the task so I made a new one from scratch.

Here's how I made one without a lathe. All I had was my micro mill for use and some Polycarbonate offcuts. (same stuff they use to make bullet proof glass)

Using an end mill and manually turning a dividing attachment, I was able to make the basic shape of the button.


An angled cutting bit was used to chamfer the edges to make it easier for the finger.


A smaller end mill was used to cut the finished button piece off the blank.


Here's the new button beside the old worn out rubber one.


On the pen host. I still have mixed feelings about the height. Seems to protrude too far out but not too bad.


And before anyone comments, yes, I let them use a 100mW laser for pointing at the presentation. But I covered the aperture with a piece of cardboard with a tiny pinhole to limit output power and it worked perfect for the application without blinding the audience.
Attached Thumbnails
Machined a New Button for my Pen Laser-img_0578.jpg   Machined a New Button for my Pen Laser-img_0580.jpg   Machined a New Button for my Pen Laser-img_0581.jpg   Machined a New Button for my Pen Laser-img_0584.jpg   Machined a New Button for my Pen Laser-img_0587.jpg  



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Old 08-17-2013, 04:57 AM #2
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Default Re: Machined a New Button for my Pen Laser

Nice! I kind of like the height if it was strictly a presentation laser. Would give me something to play with with my thumb as I spoke.

Edit: Tried to rep you but apparently I'm to stingy with rep and haven't spread enough around since the last time I rep'd you.
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Old 08-17-2013, 05:05 AM #3
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Default Re: Machined a New Button for my Pen Laser

Haha no problem

It's already pressed in so I can't do anything about the height anymore (other than sanding it off) I'm just worried it'll turn on inside my pocket and run the battery down.

I also like it better than the rubber button as being a hard material, the tactile feeling of the switch is more crisp and "clicky".
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Old 08-17-2013, 05:07 AM #4
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Default Re: Machined a New Button for my Pen Laser

I do prefer a good click on over a "mush" on button.
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Old 08-17-2013, 07:15 AM #5
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Thumbs down Re: Machined a New Button for my Pen Laser

Quote:
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Edit: Tried to rep you but apparently I'm to stingy with rep and haven't spread enough around since the last time I rep'd you.
I VOLUNTEER AS TRIBUTE!!!!

In all seriousness, this is an awesome mod and creative solution to a wear and tear problem!
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Old 08-17-2013, 07:21 AM #6
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Default Re: Machined a New Button for my Pen Laser

I attempted to rep you wannaburn for the humor of it. Can't rep you for the same exact reason.....
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Old 08-17-2013, 07:29 AM #7
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Default Re: Machined a New Button for my Pen Laser

Aw shucks was worth the try
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Old 08-17-2013, 07:51 AM #8
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Default Re: Machined a New Button for my Pen Laser

Ok I will take one for the team you can rep me
Oh very nice work on the button.
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Old 08-17-2013, 06:56 PM #9
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Default Re: Machined a New Button for my Pen Laser

Decided to be generous today. +Repped you guys for the humor haha
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Old 08-17-2013, 08:21 PM #10
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Default Re: Machined a New Button for my Pen Laser

Wow! Good job on the machining, I dread to even think about machining something that tiny

Did you polish it up after, or is that the raw look?
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Old 08-18-2013, 01:33 AM #11
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Default Re: Machined a New Button for my Pen Laser

Thanks, no polishing just the raw machined look. Since polycarbonate is softer than acrylic (perspex) it will eventually get polished by normal handling and from rubbing inside the pocket.

And since they were cooking some BBQ and smoke got in the house, I decided to take pics of the four RGBV pens.

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Old 08-18-2013, 03:23 AM #12
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Default Re: Machined a New Button for my Pen Laser

Quote:
Originally Posted by djQUAN View Post
Thanks, no polishing just the raw machined look. Since polycarbonate is softer than acrylic (perspex) it will eventually get polished by normal handling and from rubbing inside the pocket.

And since they were cooking some BBQ and smoke got in the house, I decided to take pics of the four RGBV pens.

Nice job! +rep
Are those the cheapbay ones? I saw your review about those cheapbay pens and and before I even saw your LPM on the third laser my thumb had already found the send payment button!
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Old 08-18-2013, 03:50 AM #13
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Default Re: Machined a New Button for my Pen Laser

Yup! I had the 405nm in there too but the camera didn't capture it well. You can see the faint beam towards the lower left of the pic.
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Old 08-18-2013, 05:46 AM #14
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Default Re: Machined a New Button for my Pen Laser

Great job on the button a lot of effort and great fix to an annoying issue +1 if system allows
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