In my test and review of the rotational adapter, I mentioned my Emergency Deadline Detector. Everybody has one of those. It is usually in the form of system failure or mechanical breakdowns just as you are approaching a deadline. In my case, it was a double deadline - finishing the adapter test and writeup and craft show I have to do on Thursday - need to finish a lot of product before the.
It started with the office this past week - everything that could go wrong did. And since I am on call 24/7 (even when on vacation), it meant about 70 hours of work instead of the usual 55 or so.
Today, I was working on product for the craft show. Everything was going really well. Then, all of a sudden, I was getting a very weak beam at the workpiece, and I noticed it was actually a double beam. My first thought was dirty optics, so I clean the mirrors, which needed it, but did not fix the issue. So - remove the air assist and remove the lens to clean it. To my surprise, the lens was in pieces.
[Photo - shattered lens]
Don't know what caused it, but there it was.
When I built the new laser, I stared out with the old optics to ensure I did not screw up new mirrors and lens during the build and initial alignment process. I've been meaning to swap them out for the new ones I had waiting, but had not gotten to it yet. SO, I happen to have a brand new lens just waiting for me. I put it in and everything is great.
I also noticed that the locking nuts on the mirror #2 adjustment screws were loose and vibrating. (Everybody go check yours now.) I did not swap out the mirrors yet - everything is working well and I don't want to take time to go through re-alignment if it moves while installing the new mirrors. When I do, I will re-align and then make sure the nuts are all tight.
Lesson? Keep extra optics around just in case.