DIY 3D Printable Spark Arrestor for Fiber Laser Dust Collection

Joshua Miller
Aug 15
2 min read

Updated: Sep 2

The Problem

When cutting aluminum with a fiber laser, the fine aluminum powder created can be highly flammable or even explosive - similar to a thermite reaction. This risk increases significantly when switching between aluminum and ferrous metals, as residual aluminum dust can ignite from sparks generated during steel cutting.

The Solution

Inspired by commercial units like the Nordfab In-line Spark Trap, I designed a 3D printable turbine-style spark arrestor that creates turbulence and spins the air to cool and extinguish sparks before they reach the dust collector.

Build Cost Breakdown:

Sheet metal fabrication: $262.20
McMaster-Carr components: $638.10
3D printed turbine component
Total: ~$900

McMaster-Carr Parts List:

1761K139: 12" Galvanized Steel Clamp - Qty 2 @ $23.79 = $47.58
1761K179: 12" Duct-to-Duct Adapter - Qty 4 @ $62.25 = $249.00
1761K379: 18" Duct-to-Duct Adapter - Qty 4 @ $71.00 = $284.00
1761K101: 18" Galvanized Steel Clamp - Qty 2 @ $28.76 = $57.52

Assembly Tip: Use mastic to seal all seams in the ductwork for optimal performance.

How It Works

Like commercial spark traps, this design disrupts the airflow. The 3D printed turbine creates rotational turbulence, causing sparks to lose energy and extinguish.

Critical Safety Notes

⚠️ This design is EXPERIMENTAL and NOT CERTIFIED

For production environments, use certified commercial units (Nordfab or McMaster-Carr 1761K327)
This is a COMPLEMENTARY device - not a replacement for proper safety procedures
Machine cleanliness and maintenance are your primary defense
Design is for INTERNAL USE ONLY - no commercial manufacturing

Download

By downloading, you accept this is an untested design inspired by commercial products, not equivalent to them.

Remember: Commercial spark arrestors exist for a reason - they're tested and certified. This DIY approach is for educational/experimental use only.