A Step-by-Step Guide to Setting Up Your Rotary in LightBurn for Galvo Lasers

By EM-Smart.StoreJanuary 20, 2024

Using a rotary attachment with a Galvo laser allows you to engrave and cut cylindrical objects with precision and ease. But setting it up correctly can feel daunting - until now.

This comprehensive guide breaks down every step of the LightBurn rotary setup process, from connecting the device to mastering advanced techniques. Whether you're a beginner or a seasoned pro, you'll find valuable tips and tricks to achieve stunning results on tumblers, mugs, bottles, and more.

Ensuring Compatibility with Your Galvo Laser

Before you get started with the rotary setup in LightBurn, it is crucial to verify that your Galvo laser machine is compatible with a rotary device. There are two major components to consider for compatibility—first, the physical aspect, which involves having an external rotary axis, either a chuck or roller type.

Besides, confirm the internal support from your laser machine's control board for a rotary function.
Not all Galvo laser systems come with a rotary function out of the box. It's essential to check your laser's specifications or consult with the manufacturer to confirm that your machine's control board can interface with and control a rotary axis.

Get Your LightBurn Software Ready on Computer and Up-to-Date

Ensure your computer is connected to your laser and LightBurn is installed. For a seamless experience, it's recommended to use the latest version of LightBurn software. This ensures you have access to the most recent features and bug fixes. You can download the latest version directly from the LightBurn website: https://lightburnsoftware.com/

Setting Up Your Rotary in LightBurn

Rotary devices are essential for engraving cylindrical or rounded objects. They rotate the piece so that the laser can engrave across the surface evenly. LightBurn software has incorporated features to make this process intuitive and straightforward for Galvo laser users.
Now, let's dive into the heart of the setup.

Step 1: Open the Rotary Settings Panel

Go to "Laser Tools" in LightBurn and click on "Rotary Setup."

You can also use the keyboard shortcut: Control (or Command) + Shift + R, or Cmd+Shift+R, for Mac users.

Step 2: Choose Your Rotary Type

There are generally two types of rotary attachments: chuck and roller. The chuck style grips the object, much like a lathe, while the roller style sits the object on top of wheels. Your choice will dictate the setup process in LightBurn.

Rotary Setup for Galvo (with chuck)

Rotary Setup for Galvo (with rollers)

Step 3: Configure Rotary Parameters

1.Configure the Rotary Axis

Choose whether the rotation is around the X or Y axis, depending on your rotary's orientation. If rotation is backwards or sliced incorrectly, toggling the 'Reverse Rotary Direction' switch may be necessary.

2.Determine the Steps per Rotation

Identify the “Steps per Rotation” value, which is how many motor steps are required for the rotary to complete a full 360-degree turn. This can usually be found in the documentation provided by your machine's manufacturer or determined by using the 'Test' button in LightBurn. For Instance, Steps per Rotation for EM-Smart laser engraver is 25,000.

Here's how to test:

Place a piece of masking tape on the chuck or roller, as close to the mounting point as possible.
Place another piece of tape on the mounting point.
Mark reference points on both tapes with a ruler.
In LightBurn, go to "Test" and observe how much the rotary moves.

If it completes more than one rotation, the "Millimeters Per Rotation" value is too high. Reduce it until the rotary completes one full rotation.

If the rotary doesn't complete one full rotation, the value is too low. Increase it until it does.

3.Speeds and Acceleration

Set the minimum and maximum speeds for the rotary's movement, measured in pulses per second, and define the acceleration time - which is how quickly it ramps up from the minimum to maximum speed. Additionally, you need to set the 'Return speed', which is the rate at which the rotary returns to its starting point after a rotation.

4.Input Object Diameter

Measure the diameter of the object you're engraving using a digital caliper or ruler. A caliper provides the most accurate measurement.

Enter the diameter into the "Object Diameter" field in LightBurn. The "Circumference" field will automatically update.

5.Split Setup

LightBurn’s 'Split Setup' feature is designed for Galvo markers, allowing the job to be divided into smaller parts or slices. This process involves rotating the object after each slice is completed and then moving on to the next slice.

6.Split Size

Each part of the job is called a 'Split Size'. If your object has a tapered or irregular shape, or if it’s not perfectly aligned with the rotary axis, using a smaller split size can help minimize gaps or misalignments between the slices. While a larger split size can reduce the time it takes to run the job, it might be more challenging to avoid overlaps or gaps in the finished product.

7. Overlap
To help eliminate visible gaps between slices, you can tell LightBurn to overlap them - specifying an overlap of zero means that each slice is run on its own. A non-zero overlap value will produce that much overlap on the ends of each slice, like this:

For removing paint, anodizing, or other surface coatings, use a small overlap.

For annealing or directly marking the material, adding overlaps might cause visible artifacts.

Step 4. Running the Job

When rotary mode is enabled and you press the Start button on the main window, the Rotary Marking window will appear. Here’s what you can do from this window:

Tune Split Size, Overlap, and Object Diameter: Adjust these settings to suit your project’s needs.

Jog the Rotary: Move the rotary to check alignment and positioning.
Run the Job: Start the laser job.

Step 5. Centering and Sanity Check

When running a rotary job, the center of your page is considered the current rotary position when you clicked 'Start'. Use the 'Sanity Check' button to catch any common mistakes. This step acts as a final review before you run the laser, supplementing your preview and framing process.

By following these steps and tips, you can optimize your rotary laser jobs in LightBurn for better accuracy and quality.

Additional Tips for Rotary Engraving Success

Tilting the Rotary: For tumblers or objects with sloped surfaces, you can tilt the entire rotary to make the top surface level with the laser for more even engravings.
Speed and Power: Experiment with different laser speeds and power settings to find the optimal combination for your material.
Rotary vs. Chuck: Use a roller for cylindrical objects with a regular shape (tumblers, bottles, etc.). Use a chuck for mugs with handles, rings, or spherical objects. Some rotaries are convertible, allowing you to switch between chuck and roller configurations.

LightBurn Rotary Setup FAQs

Let's tackle some common challenges you might encounter when setting up and using your rotary attachment in LightBurn:

Q: My engraving appears off-center or distorted. What can I do?

Misalignment is a common issue, and it's usually due to one of these factors:

Rotary Calibration: Double-check that you've accurately calibrated your rotary using the steps outlined earlier. Incorrect measurements can lead to misalignment.

For EM-Smart laser engraving machines, you can directly import the file "markcfg7", which contains all the calibration parameters and port settings for your machine.

Workpiece Alignment: Ensure your workpiece is securely clamped or positioned on the rotary and that it's perfectly aligned with the laser head. Use your marked reference points or the mold line for guidance.
Laser Head Positioning: Make sure your laser head is properly positioned and that it's moving smoothly along the X-axis. Any obstructions or misalignment in the laser head's movement can cause distortions.

Q: I need to engrave objects with different diameters. Do I have to recalibrate the rotary each time?

You'll need to adjust the "Object Diameter" setting in LightBurn for each new object. Here's how:

Chuck Rotary: Every time you change the object, you'll need to re-enter the new diameter in the "Object Diameter" field in LightBurn's Rotary settings. LightBurn will automatically calculate the new circumference based on the diameter.

Roller Rotary: You only need to adjust the "Object Diameter" setting once for your roller setup. The roller's circumference is determined by its own diameter, not the object's.

Q: How can I get the best engraving or cutting results on different materials?

The key to optimizing your results is adjusting the laser power, speed, and other settings based on the material you're working with. For different brands of laser machines, you can refer to the official parameter guidelines provided by the manufacturer. Here you can find the recommended material settings on EM-Smart laser, helping you achieve the best possible results.

Rotary Engraving with LightBurn Samples

With a Galvo laser and LightBurn software's rotary setup, you can easily engrave intricate designs, logos, or even custom messages onto cups, rings, and other cylindrical items.

Here are some examples of what you can achieve with rotary engraving.

Personalized Mugs: Create custom coffee mugs with meaningful messages, inspiring quotes, or even intricate artwork. Imagine a mug with a beautiful floral design or a funny quote that makes your friend smile every morning.
Unique Rings: Engrave rings with special dates, symbols, or personalized messages to create one-of-a-kind gifts. Think of a ring with a delicate floral pattern or a special date engraved around the band, making it a truly unique and meaningful piece of jewelry.
Custom Water Bottles: Add a touch of personality to water bottles with unique designs, patterns, or logos. Imagine a water bottle with a nature-inspired design, a personalized monogram, or a fun quote that reflects your personality.

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