The development of cheaper, more powerful lasers has always been a cause for excitement among hackers, and fiber lasers are no exception. One of the newer tools they’ve enabled is the laser welder, which can be used to weld, cut through metal, or clean off surfaces. Or, as [Cranktown City] demonstrated, you can use one to build a metal 3D printer.

The printer’s built around a 2000-Watt fiber laser welder from Skyfire, and the motion system came from a defunct secondhand 3D printer built by an out-of-business insole printing company. The frame was reinforced with steel, the welding gun was mounted in place of the hotend, and the trigger was replaced with a CNC-controlled switch. It didn’t originally use any specific shielding gas, since the welder was supposed to perform adequately with just compressed air if high weld quality wasn’t essential.

The first few tests were promising, but did reveal quite a few problems. Heat buildup was an early issue which threatened to warp the build plate, and which eventually welded the build plate to the Z-axis gantry. Adding a strong cooling fan and putting a gap between the build plate and the gantry solved this. The wire also kept getting stuck to the build surface, which [Cranktown City] solved by pausing the wire feed and pulling it away from the part when a layer finished. Simply using compressed air led to a weak deposit that cracked easily, and while a nitrogen stream improved the print somewhat, argon shielding gas gave the best results. For his final print, [Cranktown City] made a vase. The layers were a bit crude, but better than most welder-based metal printers, and the system shows some real promise.

We’ve seen a few printers built around welders before, and a few built around lasers, but this seems to be the first to use both.

PostmarketOS is a Linux distribution specifically designed for those who wish to repurpose old smartphones as general-use computers, to a degree. This can be a great way to reuse old hardware. However, for [Bry50], it was somewhat discomforting leaving the phone’s aging lithium battery perpetually on charge. A bit of code was thus whipped up to provide a greater measure of safety.

The concept is simple enough—lithium batteries are at lower risk of surprise combustion events if they’re held at a lower state of charge. To this end, [Bry50] modified the device tree in PostmarketOS to change the maximum charge level. Apparently, maximum charge was set at a lofty 4.4V (100%), but this was reconfigured to a lower level of 3.8V, corresponding to a roughly 40-50% state of charge. The idea is that this is a much healthier way to maintain a battery hooked up to power for long periods of time. There’s one small hitch—the system will get confused if the battery voltage is higher than the 3.8 V setpoint when switching over. It’s thus important to let the device discharge to a lower level if you choose to make this change.

It’s a neat mod that both increases safety, but keeps the battery on hand to let the system ride through minor power outages. If you’re new to the world of repurposing old smartphones, fear not. [Bryan] also has a tutorial on getting started with PostmarketOS for the unfamiliar. If you’re working on your own projects in this space, we’d love to hear about them—so get on over to the tipsline!