Hexastorm PCB
KiCad design files for the Hexastorm, an open-hardware prism laser direct imager. This project utilizes an ESP32-S3 and an iCE40 UP5K FPGA to achieve high-resolution, high-speed laser exposure.
The design files are organized into two primary categories:
1. Laser Module
Contains the PCBs that form the actual laser head as depicted in the CAD design.
- Prism Drive: Specialized PCBs designed to spin the optical prism using either a standard BLDC motor or an integrated PCB motor.
- Laser Control: Localized circuitry for high-speed modulation of the laser diode.
2. Base System
The Base system has been consolidated into a single-board architecture, designed as a drop-in replacement for the Vevor Pro CNC3018 controller. It handles high-speed logic, power distribution, and motion control on a single PCB.
- MCU: ESP32-S3 (N32R8V) utilizing 8MB Octal PSRAM for rapid image buffering.
- FPGA: Lattice iCE40 UltraPlus 5k (UP5K) for nanosecond-level laser modulation and real-time synchronization with the prism index pulses.
- Vision & Alignment: Features a dedicated 24-pin FPC camera connector supporting the OV2640 sensor for precise laser alignment.
- Motion Control: Headers for 3x Stepper Motor Drivers (e.g., TMC2209) for X, Y, and Z/Focus axes with sensorless homing.
- Laser Support: Interface for one laser module.
- Power Management: * Supports 24V input.
- Integrated DC-DC conversion to 12V for the laser module and cooling system.
- PWM Fan Control for active thermal management.
- Connectivity: USB-C for high-speed data transfer and firmware updates.
Resources & Links
- Progress Updates: Follow the development blog on Hackaday.io.
- BOM & Costing: Spreadsheets can be generated using KiCost.
- CAD Design: 3D files for the mechanical assembly are available here.
Status
Several generations of the system have been prototyped. A successful high-resolution exposure can be seen in this demonstration video.
Latest single-board design is currently in the testing phase.