Safety and operational enhancements in a laser machine

Abstract

Embodiments of the present disclosure relate to apparatuses for use in laser machines, and laser machines incorporating the same. In one embodiment, a safety enhancement apparatus for a laser machine comprises an outer panel defining a feeder slot configured for the insertion of a material to be processed, and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the inserted material. In a further embodiment, a feeder apparatus for a laser machine comprises a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot.

Description

SAFETY AND OPERATIONAL ENHANCEMENTS IN A LASER MACHINECROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] The present application claims the benefit of priority of U.S. Provisional Patent Application Nos. 63 / 678,556, filed August 2, 2024, and 63 / 678,552, filed August 2, 2024, the disclosures of which are hereby incorporated by reference herein in their entireties.TECHNICAL FIELD

[0002] The present disclosure relates to laser machines and, more particularly, to laser cutting machines and components thereof.BACKGROUND

[0003] Laser machines have become indispensable tools in various industries, including manufacturing, engraving, cutting, and marking. These machines utilize high-intensity laser beams for precise material processing, often involving the cutting, engraving, or etching of different materials, such as metals, plastics, and composites.

[0004] During material processing, the laser head emits a powerful beam that interacts with the workpiece, leading to the desired results. However, the process generates smoke, debris, and contaminants, which can pose significant challenges to the functionality and longevity of the laser machine. These contaminants can accumulate on sensitive optical components, such as lenses and mirrors, leading to a degradation in laser beam quality, reduced processing efficiency, and increased maintenance needs.

[0005] Efforts to mitigate these challenges have led to the development of various protective measures, including air curtains. While these protective measures have shown some success in reducing contamination, there remains a need for improved solutions that provide comprehensive protection for the laser head and optical components while allowing for the efficient operation of the laser machine.

[0006] In addition to concerns regarding contamination of optical components, there is a need for advancements in the safety and functionality of material feeding mechanisms within laser machines. Existing devices often lack adequate safeguards to prevent accidental exposure to the laser beam during material loading and unloading, which can pose risks to operators and compromise the integrity of the processed materials. Furthermore, conventional feeding mechanisms may not provide sufficient precision or adaptability to accommodate a wide range of material types and thicknesses, potentially limiting the versatility and efficiency of the laser machine.SUMMARY

[0007] The following presents a simplified summary of various aspects of the present disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of the disclosure. It is intended to neither identify key or critical elements of the disclosure, nor delineate any scope of the particular embodiments of the disclosure or any scope of the claims. Its sole purpose is to present some concepts of the disclosure in a simplified form as a prelude to the more detailed description that is presented later.

[0008] A first aspect of the present disclosure relates to a cover adapted for protecting components of a laser machine. In at least one embodiment, the cover comprises: a body having an elongated shape and being adapted to couple to a gantry of a laser machine; and at least one flexible member coupled to an edge of the body, the body, when coupled to the gantry, defining an internal cavity and a channel that spans opposing ends of the body, and the at least one flexible member being adapted to at least partially cover the channel.

[0009] A second aspect of the present disclosure relates to a laser cutting machine. In at least one embodiment, the laser cutting machine comprises: a frame comprising opposing sides coupled together by a plurality of rigid structural members; an external housing supported on the frame; a laser apparatus; and a cover coupled to the laser apparatus to define an internal cavity and a channel. In at least one embodiment, the laser apparatus comprises: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry; a laser head moveably coupled to and constrained to move along the longitudinal rail. In at least one embodiment, the cover comprises: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel. In at least one embodiment, the motorized longitudinal rail is substantially contained within the internal cavity. In at least one embodiment, the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

[0010] A third aspect of the present disclosure relates to an apparatus comprising: a longitudinal rail; a laser head moveably coupled to and constrained to move along the longitudinal rail; and a cover as described above.

[0011] A fourth aspect of the present disclosure relates to a safety enhancement apparatus for a laser machine, the apparatus comprising: an outer panel defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

[0012] A fifth aspect of the present disclosure relates to a laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; a laser apparatus comprising a laser head; a feeder apparatus; a external housing supported on the frame and encompassing the laser apparatus and the feeder apparatus; and a safety enhancement apparatus comprising: an outer panel integrated with the external housing and defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

[0013] A sixth aspect of the present disclosure relates to a feeder apparatus for a laser machine, the feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized.

[0014] A seventh aspect of the present disclosure relates to a laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; a laser apparatus comprising a laser head; and a feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material.

[0015] An eighth aspect of the present disclosure relates to a method comprising: providing an outer panel defining a feeder slot configured for insertion of a material to be processed; positioning one or more movable inner panels inside the feeder slot, each movable inner panel being adjustable to conform to the shape and / or size of the material; detecting, by one or more sensors, one or more physical parameters of the material; and causing, by a processing device operatively coupled to the sensors and the movable inner panels, the movable inner panels to move and adjust based on data generated by the one or more sensors.

[0016] A ninth aspect of the present disclosure relates to a method comprising: providing a plurality of rollers defining a feed path and configured to transport a material into a laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, at least one of the plurality of rollers is disposed above the feed path, and at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material as determined by oneor more sensors; and causing, by a processing device, the rollers to be actuated and adjusted based on data generated by the one or more sensors to conform to the properties of the material.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present disclosure is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings, in which:

[0018] FIG. 1 shows an exploded view of an apparatus comprising an exemplary cover, in accordance with at least one embodiment;

[0019] FIG. 2 shows an orthographic view of an apparatus that includes the assembled cover, in accordance with at least one embodiment;

[0020] FIG. 3 shows the apparatus cover which includes flexible members that cover a channel, in accordance with at least one embodiment;

[0021] FIG. 4 shows a cross-sectional view of the apparatus to show a laser head housed within the exemplary cover, in accordance with at least one embodiment;

[0022] FIG. 5 shows a cross-sectional view of a variation of the apparatus for which an additional sealing mechanism is utilized, in accordance with at least one embodiment;

[0023] FIG. 6 shows an orthographic view of an exemplary frame, in accordance with at least one embodiment;

[0024] FIG. 7A shows the exemplary apparatus integrated into the exemplary frame, in accordance with at least one embodiment;

[0025] FIG. 7B shows a first cutaway view of the coupling between the laser apparatus and the frame, in accordance with at least one embodiment;

[0026] FIG. 7C shows a second cutaway view of the coupling between the laser apparatus and the frame, in accordance with at least one embodiment; and

[0027] FIG. 8 shows an orthographic view of an assembled exemplary laser cutting device, in accordance with at least one embodiment.

[0028] FIG. 9A shows a front view of components of an exemplary safety enhancement apparatus, in accordance with at least one embodiment.

[0029] FIG. 9B shows the components of the exemplary safety enhancement apparatus such that a movable panel is displaced to cover a gap between rollers and a sheet of material inserted therein, in accordance with at least one embodiment.

[0030] FIG. 10 illustrates a variation of the exemplary safety enhancement apparatus, in accordance with at least one embodiment.

[0031] FIG. 11 illustrates a cross-sectional view components of an exemplary feeder apparatus, in accordance with at least one embodiment

[0032] FIG. 12 shows a exemplary computer system for use with the various embodiments described herein.DETAILED DESCRIPTION

[0033] Described herein are embodiments related to a cover to protect the internal components (e.g., optics, rails, etc.) of a laser machine, as well as devices and apparatuses incorporating the same. The embodiments further relate to a cover having one or more of a modular design, integrated lighting, a double-sealing mechanism, and an exhaust systems, each of which contributing to the enhanced functionality and longevity of laser machines used for materials processing.

[0034] In at least one embodiment, the cover features one or more flexible members (e.g., one or more rubber strips) that serve as a protective barrier, safeguarding the laser head, optics, and rails from contamination generated during laser material processing.

[0035] In addition to the flexible members, embodiments of the present invention introduce several features to enhance the functionality and convenience of the cover. These may include, but are not limited to, a modular design that facilitates easy maintenance and replacement, integrated lights, such as light-emitting diode (LED) lights, for workspace illumination and / or device status indication, a double-sealing mechanism for added protection against contaminants, and an exhaust system for efficient contaminant removal. In at least one embodiment, the cover allows the laser beam to travel outside the cover to provide uninterrupted material processing.

[0036] In at least one embodiment, the cover for laser cutting machines includes channel for laser beam transmission, which may be sealed or partially sealed by at least one flexible member such as an elastic strip, brush, way cover, or similar element, allowing movement of a laser head while preventing contamination into the cover. In at least one embodiment, the flexible member may be designed to maintain a barrier against contaminants while enabling the laser to interact with the processing material.

[0037] In at least one embodiment, the modular design for the cover includes two or more pieces, facilitating easy maintenance, manufacturing, and assembly. In at least one embodiment, the individual pieces can be disassembled and reassembled for convenient maintenance and replacement. In at least one embodiment, the integration of LED lights within the cover can provide for illumination of the work area and / or status indications.

[0038] In at least one embodiment, a double-sealing mechanism is incorporated into the axis cover, featuring two overlapping flexible members and / or a ring on the nozzle of the laser head to provide an additional layer of protection against contaminants. In at least one embodiment, anexhaust system is integrated with the cover or a portion thereof, designed to connect to an exhaust fan for efficient contaminant removal.

[0039] In at least one embodiment, the protection of the laser head and optical components is further enhanced by a unique mechanism for deflecting the rubber strip when the axes of the laser machine are in motion. This mechanism serves to ensure that the flexible member does not impede the movement of the laser head or the overall operation of the machine. In at least one embodiment, this deflection is achieved by incorporating a protruding part that is connected to the rail or part of the laser head. This protruding part is strategically positioned to make contact with the flexible member(s) when the axes are in motion, gently pushing the flexible member(s) aside to create an unobstructed path for the laser. This feature allows for seamless and uninterrupted laser material processing, as the flexible members automatically yields to the moving parts, maintaining an effective barrier against contamination while facilitating the free movement of the laser head.

[0040] Additionally, in at least one embodiment, the deflection of one or more flexible members along the body can also be achieved by the laser head or nozzle itself. When the laser head moves, it may contact a portion of the flexible members and deflect them temporarily. This dynamic interaction ensures that the laser head can traverse the work area without hindrance while still benefiting from the protective barrier provided by the flexible members.

[0041] Thus, various embodiments described herein advantageously improve the efficiency, longevity, and reliability of laser machines used for material processing while minimizing downtime and maintenance requirements. Further, while described in the context of laser machines, such as laser cutting machines, the embodiments are versatile and can be applied to other types of laser devices, such as computer numerical control (CNC) milling machines and three-dimensional (3D) printer machines, as well as to other industries such as traditional printed technologies.

[0042] Further embodiments of the present disclosure relate to a frame for supporting components of a laser machine. Laser cutting machines, in particular, are essential in industrial and manufacturing settings for their precision, speed, and versatility. However, conventional frames, which are often comprised of multiple parts, can complicate assembly, introduce alignment errors, and reduce rigidity, ultimately impacting machine accuracy and reliability. The need to attach panels for enclosure further complicates assembly and may not provide optimal structural support. These challenges highlight the need for an improved frame structure that enhances accuracy, rigidity, ease of assembly, and overall reliability in laser cutting machines.

[0043] Embodiments of the present disclosure addresses these shortcomings by utilizing a cover comprising two sides, each manufactured as a single, monolithic part from a rigid and robust material. This streamlined construction eliminates complex component connections, significantly enhances rigidity, simplifies assembly, and reduces the potential for user errors. As a result, the machine achieves improved accuracy, speed, and precision. The two monolithic sides can be connected using various structural elements, such as profiles, beams, panels, or rods, further enhancing stability and allowing for easy disassembly and reassembly. The frame also accommodates the attachment of panels to create an enclosure, addressing environmental control and user safety. While described in the context of laser cutting machines, the frame can also be effectively applied to other machines, such as CNC milling machines and 3D printers.

[0044] Further embodiments of the present disclosure relate to a safety enhancement apparatus for a laser machine and. The apparatus may be integrated directly into any one of the laser machine embodiments described herein, and may be designed to enable compliance with Class 1 safety regulations while supporting efficient and precise cutting of materials by utilizing movable panels equipped with proximity or pressure sensors.

[0045] Laser cutting technology is widely used for its ability to precisely cut a variety of materials. However, laser cutting devices present significant safety risks, including exposure to laser radiation, smoke, and material debris. To address these hazards, laser cutting devices are classified into safety classes, with Class 1 being the safest and requiring no additional protective measures or enclosures. For laser cutters with material pass-through openings, maintaining Class 1 compliance while preserving the flexibility to work with different materials and thicknesses can be challenging. Existing solutions, such as fixed enclosures, often reduce the machine’s versatility and can thus hinder workflow efficiency.

[0046] In at least one embodiment, an apparatus features movable panels equipped with proximity or pressure sensors, which together ensure Class 1 safety compliance and optimize material processing. For example, in at least one embodiment, the system features four movable panels arranged around the material pass-through opening of the laser cutter. These panels can be adjusted to fit a variety of material sizes and shapes. In at least one embodiment, each panel is equipped with one or more proximity sensors or one or more pressure sensors that detect the presence and position of the material being processed. In at least one embodiment, the apparatus causes all panels to be in contact the loaded material before the laser of the laser machine can be operated to ensure proper alignment and safety. In at least one embodiment, the apparatus provides both manual and automatic adjustment options for the panels. Operators (also referred to herein as “users”) can manually position and align the panels as needed. In at least one embodiment, automatic mechanisms, such as springs, motors, elastic materials, or combinationsthereof can be used to adjust the panels, ensuring that any gaps between the panels and the material are eliminated.

[0047] Embodiments of the safety enhancement apparatus advantageously incorporate movable panels and sensors to ensure Class 1 safety compliance, thereby minimizing the risk of laser exposure and associated hazards. The apparatus is advantageously designed to accommodate a wide range of material sizes and shapes, making it suitable for diverse laser cutting applications, and can be implemented in various embodiments to achieve its intended objectives for laser cutting machines with material pass-through openings.

[0048] In at least one embodiment, the panels are mounted on adjustable brackets or arms that allow for easy positioning and secure clamping around the material pass-through opening. In at least one embodiment, proximity sensors or pressure sensors integrated into the panels can be implemented using various technologies, including infrared proximity sensors, capacitive sensors, or force-sensitive resistors (FSRs). In at least one embodiment, multiple sensors are distributed evenly along the edges of each panel to ensure accurate detection of material presence and positioning. In at least one embodiment, a manual adjustment mechanism for the panels may include hand-operated knobs, levers, or locking pins that enable precise adjustments. In at least one embodiment, an automatic adjustment mechanism employs a combination of sensors and actuators. In this embodiment, proximity sensors continuously monitor the position of the material, and if any misalignment is detected, the actuators, such as motors or springs, are triggered to automatically adjust the panel positions until proper contact with the material is achieved. In at least one embodiment, the apparatus can also operate without sensors, using springs, elastic materials, or motors to provide constant pressure against the material. The apparatus may be equipped with a control apparatus incorporating a processing device (e.g., a microcontroller, a programmable logic controller, etc.) to process sensor data and execute adjustments. To ensure compliance with Class 1 safety regulations, in at least one embodiment, the apparatus may incorporate a safety interlock apparatus. The safety interlock apparatus can prevent the laser cutter from operating unless all panels have made contact with the material and the sensors confirm their proper positioning. Visual and auditory indicators can alert operators to any issues that require attention.

[0049] Further embodiments of the present disclosure relate to a feeder apparatus for a laser machine. In at least one embodiment, the laser machine is equipped with an automatic feeder capable of advancing materials into and out of the machine. Such embodiments allow for the processing of materials longer than the depth of the laser machine itself and allow for the automatic feeding of multiple material sheets in succession.

[0050] In at least one embodiment, the material is conveyed between two or more rollers, with at least one roller being motorized to facilitate movement. In at least one embodiment, the feeder system automatically adjusts to accommodate different material thicknesses. At least one roller is connected to a piston, spring, or elastomeric element to apply force toward another roller. The applied force pinches the material between the rollers to create friction and enable movement without requiring manual adjustment for varying material thicknesses.

[0051] Laser machines play a vital role in modem manufacturing by enabling automated, precise, and repeatable processing of materials into parts and products. These machines are widely used for cutting, engraving, and shaping a variety of materials. Traditional laser machines often require manual loading, unloading, and adjustment when processing materials, especially those that vary in size and thickness or are longer than the machine itself. Such manual intervention can limit productivity and increase the risk of errors. There is a significant need for an improved automatic material feeder system for laser machines that can efficiently and autonomously handle materials of various thicknesses and lengths.

[0052] The feeder apparatus described herein may be used in various types of laser machines, including but not limited to laser cutters, CNC milling machines, and 3D printers. In at least one embodiment, the feeder apparatus comprises a set of rollers positioned at the entry or exit points of the laser machine, with the rollers being configured to transport material into and out of the laser machine. At least one roller in each may be motorized, enabling the movement of material through the machine. The embodiments described herein advantageously enhance operational efficiency, reduce the need for manual intervention, and improve the accuracy and quality of the machining process across a range of laser applications, including cutting and engraving.

[0053] An advantageous feature of the feeder apparatus is its capability to automatically adjust to varying material thicknesses. This may be accomplished through an adjustment mechanism comprising at least one adjustable roller. The adjustable roller may be mounted on a movable assembly, which may include, but is not limited to, pistons, springs, or elastomeric elements. In at least one embodiment, the movable assembly applies a variable force to the adjustable roller to press the material against an opposing roller. This applied pressure generates sufficient friction to transport the material through the laser machine without requiring manual adjustment.

[0054] The feeder apparatus is particularly advantageous for processing materials that exceed the depth of the laser machine. The automatic feeder can sequentially advance the material through the machining area, enabling continuous operation. This configuration isespecially beneficial for applications involving the processing of large sheets or the sequential feeding of multiple smaller sheets without operator intervention.

[0055] In at least one embodiment, a system includes a roller platform that supports the material and is mechanically connected to the laser machine. The roller is designed to remain stable without the need for additional legs or supports on the underlying surface, supporting the material being fed into the laser machine while conserving workspace and permitting the use of a compact work surface. In at least one embodiment, the roller platform is connected to the laser machine via a hinge mechanism, which allows the user to position the roller from a lowered to a raised orientation and secure it at various heights. This hinge mechanism enables straightforward adjustment of the roller height, accommodating different material thicknesses and providing flexibility in workspace configuration.

[0056] In at least one embodiment, the feeder apparatus is equipped with a control system that regulates the operation of the motorized rollers and the adjustable mechanism. The control system (e.g., a processing device) can be programmed with parameters corresponding to different material types and thicknesses, enabling the system to automatically select appropriate settings for a given material. The feeder apparatus may utilize the same control system as the laser machine or operate with a dedicated control unit.

[0057] In at least one embodiment, the feeder apparatus may incorporate sensors, cameras, manual input, or other detection methods to identify the type or properties of the material, such as hardness. This information enables the control system to adjust the pressure applied by the adjustable roller assembly according to the detected material properties, ensuring optimal friction and precise material handling under varying conditions.

[0058] While the embodiments described above focus on the core functionality of the feeder apparatus, additional features and variations may be integrated to enhance its utility and performance. For example, in at least one embodiment, the feeder apparatus may include mechanisms to ensure precise alignment of materials as they are fed into the laser machine, thus reducing waste and improving the quality of the finished product. Furthermore, the feeder apparatus may be designed for straightforward integration with various types of laser machinery and adaptability to different operational scales, ranging from small workshops to large-scale industrial manufacturing environments.

[0059] FIG. 1 shows an exploded view of an apparatus 100 comprising a gantry 105 and an exemplary cover 110, in accordance with at least one embodiment. In at least one embodiment, the gantry 105 is a component of a laser machine that defines a longitudinal axis (“x-axis”). As illustrated, the apparatus 100 is formed from the gantry 105 and the cover 110, which define openings 112A and 112B at the opposing of the apparatus 100 when coupled to each other (e.g.,by a snap-fit coupling or other mechanical coupling mechanism), facilitating easy maintenance, manufacturing, and assembly. When assembled, the apparatus 100 will have an elongated shape that defines an internal cavity 120 and a channel 130 that spans opposing ends of the apparatus 100. In at least one embodiment, the cover 110 is formed from a single monolithic material rather than from separate pieces. In other embodiments, the cover 110 is formed from two or more pieces. In at least one embodiment, the material of the body or any pieces thereof are formed from a rigid material, such as a metal (e.g., stainless steel, aluminum, etc.), a rigid plastic material (e.g., polypropylene, polystyrene, polycarbonate, acrylic, polyvinyl chloride), or a compositive material (e.g., a carbon fiber reinforced polymer). In at least one embodiment, the apparatus 100 can be disassembled and reassembled for convenient maintenance and replacement.

[0060] The dimensions of the cover 110, when coupled to the gantry 105, may be selected to match the dimensions of the gantry 105 as well as optical components and other components to be housed therein. For example, in at least one embodiment, the depth (along the longitudinal direction) of the apparatus 100 is about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, about 100 cm, about 110 cm, about 120 cm, about 130 cm, about 140 cm, about 150 cm, or in any range defined by and inclusive of these points (e.g., from about 80 cm to about 120 cm). In at least one embodiment, a length and height of the apparatus 100 may be independently selected from about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, about 10 cm, about 11 cm, about 12 cm, about 13 cm, about 14 cm, about 15 cm, about 16 cm, about 17 cm, about 18 cm, about 19 cm, about 20 cm, or in any range defined by and inclusive of these points (e.g., from about 6 cm to about 12 cm).

[0061] In at least one embodiment, the gantry 105 includes a panel 150 that may be used to couple to components of a laser apparatus. For example, the panel 150 is shown as a surface extending from an internal wall of the gantry 105, though other arrangements and orientations may be utilized depending on the structure of the laser apparatus to be enclosed, as would be appreciated by those of ordinary skill in the art. In at least one embodiment, multiple panels may be present.

[0062] FIG. 2 shows an orthographic view of an apparatus 200 that includes the cover 110, in accordance with at least one embodiment. In at least one embodiment, a laser apparatus 210 comprises a motorized longitudinal rail 220 coupled to the gantry 105 via the panel 150, with the entire laser apparatus 210 being substantially enclosed within the internal cavity 120. The laser apparatus includes a laser head 230 coupled to a laser mount 235 that is moveably coupled to and constrained to move along the longitudinal rail 220. During operation of a laser device in whichthe apparatus 200 is integrated, the laser head 230 is moved along the longitudinal axis (“x- axis”) of the rail 220 while irradiating an underlying target or sample.

[0063] FIG. 3 shows a bottom view of the apparatus 100 to illustrate flexible members 300A and 300B that cover the channel 130. As illustrated the flexible members 300A and 300B are coupled (e.g., by an adhesive material) to the gantry 105 and the cover 110, respectively, on opposing edges of the channel 130. As illustrated, the flexible members 300A and 300B are in contact effectively protecting the interior of the apparatus 100 from contaminants ejected toward the bottom of the cover 110. In at least one embodiment, flexible members 300A and 300B comprise a flexible rubber material, a way cover, a brush, or a combination thereof. In at least one embodiment, the flexible members 300 A and 300B run from end to end of the apparatus 100. In at least one embodiment, a single flexible member may be used, and may be coupled to one edge of the channel 130. In at least one embodiment, multiple flexible members may be coupled along the edges of the channel 130.

[0064] FIG. 4 shows a cross-sectional view of the apparatus 200 where the laser head 230 extends through the channel 130. As illustrated, components of the laser apparatus 210 may include various mechanical and optical components to move the laser head along the longitudinal rail 220. For example, a mirror 240 may be present to reflect a laser beam into the laser head 230, which may include additional optical components (e.g., lenses) to focus the laser during operation. Further as illustrated, the laser head 230 deforms and separates the flexible members 300A and 300B in the vicinity of the laser head 230. Away from the laser head 230, the flexible members 300 A and 300B remain close or in contact along the length of the channel 130 to prevent or reduce dust and debris entering the internal cavity 120 during operation of the laser apparatus 210.

[0065] In at least one embodiment, the laser apparatus 210 further comprises an exhaust vent that may be fluidly coupled to an exhaust fan of a laser device in which the laser apparatus 210 is integrated. In at least one embodiment, the exhaust vent may include openings along the length of the laser apparatus 210 to permit airflow into the exhaust vent from the internal cavity 120. The exhaust vent may further facilitate removal of contaminants generated during laser material processing.

[0066] FIG. 5 shows a cross-sectional view of a variation of the apparatus for which an additional sealing mechanism is utilized, in accordance with at least one embodiment. As illustrated, an apparatus 500 includes a gantry 505 and a cover 510 which are similar to those of the apparatus 200 except that an additional panel 540 located along an interior surface of the gantry 505, and a panel 550 extends further to adjust the location at which the gantry 505 is coupled to the laser apparatus 210. In at least one embodiment, flexible members 530A and530B are included as shown, which are coupled, respectively, to the panel 540 and an interior surface of the cover 510. In at least one embodiment, the flexible members 530A and 530B extend from end to end of the apparatus 500. Together, flexible members 520A, 520B, 530A, and 530B provide a double barrier of protection to the components housed within the apparatus 500. In at least one embodiment, any of the flexible members 520A, 520B, 530A, and 530B may be similar to the flexible members 300 A and 300B described above. In at least one embodiment, the flexible members 530A and 530B may be replaced with, or supplemented with, a flexible ring that is coupled to the laser head 530 and is sized such that it contacts or nearly contacts the panel 540 and the cover 510. In at least one embodiment, the ring is formed from a flexible rubber material, a brush, or any other suitable flexible material.

[0067] FIG. 6 shows an orthographic view of an exemplary frame 600, in accordance with at least one embodiment. The frame 600 includes monolithic sides 610A and 610B that are coupled together via longitudinal structural panels 620 and 630. In at least one embodiment, other types of structural elements, such as profiles, beams, panels, and rods, may be utilized in lieu of or in addition to the longitudinal structural panels 620 and 630. The use of the monolithic sides 610A and 610B in a laser machine can reduce assembly complexity and minimize manufacturing errors. Moreover, the registration features of the sides 610A and 610B allow for ease of attachment, and improvement in the accuracy and reliability of operation for various applications in addition to laser machining. In at least one embodiment, the frame 600 and various components thereof may be constructed from materials such as metals, alloys, or composite materials, and can be tailored to meet specific performance and durability requirements. Additionally, different manufacturing processes, including but not limited to molding, forging, CNC milling, and additive manufacturing techniques, may be employed to create one or more components of the frame 600 with precision.

[0068] In at least one embodiment, the frame 600 comprises one or more sensors and / or feedback mechanisms to monitor the structural integrity and alignment of the frame 600. These sensors can provide real-time data to a control system of the machine in which the frame 600 is integrated, enabling automatic adjustments to maintain optimal performance.

[0069] Each side 610A and 610B may include a plurality of integrated registration components, such as mounting panels, struts, etc., for mounting components of a laser machine, such as rails, optical components, electronics, and any other relevant component that would be appreciated by those of ordinary skill in the art. For example, panels 640A and 640B are integrated into the sides 610A and 610B, respectively, which may be used for mounting a rail that allows movement of a laser apparatus along a single axis. The registration components maybe strategically positioned to ensure accurate and repeatable registration of important elements, including components of multiple movement axes.

[0070] FIGS. 7A-7C illustrate integration of the apparatus 200 into the frame 600, in accordance with at least one embodiment. The frame 600 is illustrated as having additional components mounted to its various registration components. FIGS. 7B and 7C show a cutaway view of the interface between the laser apparatus 210 and the side 610B. A transverse rail 720 is mounted to the side 610B that couples to the laser apparatus 210 and allows for transverse movement of the laser apparatus 210 during operation, while the longitudinal rail (not visible) allows for longitudinal movement of the laser head 230 (not visible). A similar coupling may exist between the laser apparatus 210 and the opposing side 610A.

[0071] FIG. 8 shows an orthographic view of an assembled exemplary laser cutting device 800, in accordance with at least one embodiment, which includes the components described above. One or more additional panels may form an external housing to enclose the components of the laser cutting device 800 to provide protection from outside contaminants and for aesthetic purposes.

[0072] FIGS. 9 A and 9B show a front view of components of an exemplary safety enhancement apparatus 900, in accordance with at least one embodiment. In particular, an outer panel 902, or a portion thereof, is depicted as having a feeder slot 904 formed therethrough that allows a sheet 950 of a material to be processed to fed into a laser machine (where a crosssection of the sheet 950 is shown such that a normal of its rectangular shape is parallel to the direction in which it is fed through the feeder slot 904). For example, in at least one embodiment, the outer panel 902 is integrally formed with an external housing of the laser cutting device 800. The sheet 950 may be composed of any material suitable for laser cutting or etching, such as wood, acrylic, paper, cardboard, leather, fabric, or certain types of metal or plastic, depending on the capabilities of the laser machine. The selection of the sheet material is typically based on the intended application and the power and wavelength of the laser, ensuring that the material can be effectively and safely processed.

[0073] In at least one embodiment, a pair of rollers 910A and 910B are positioned adjacent to the feeder slot 904 such that they are configured to contact opposing surfaces of the sheet 950 as it is introduced into the apparatus 900. The rollers 910A and 910B are aligned such that, when actuated, they grip the sheet 950 securely and apply a controlled force to draw the material through the feeder slot 904 and into the laser machine. In at least one embodiment, the surfaces of rollers 910A and 910B may be coated or covered with materials such as high-friction rubber, silicone, or polyurethane to enhance grip and minimize the risk of slippage as the sheet 950 is fed through the slot 904. The choice of roller surface material may be tailored to the specifictype of sheet being processed, ensuring optimal traction and reducing the likelihood of surface marring or deformation during feeding. The rollers 910A and 91 OB may be driven by a motorized mechanism (such as described below with respect to the feeder apparatus 1100) or manually operated, depending on the specific design, and are capable of advancing the sheet 950 at a consistent rate to ensure smooth and accurate feeding. The contact pressure between the rollers 910A and 91 OB and the sheet 950 can be adjusted to accommodate different material thicknesses and to prevent slippage or damage to the material during the feeding process.

[0074] The apparatus 900 includes a movable inner panel 920 disposed behind the outer panel 902. In various embodiments, the inner panel 920 may be manually adjustable, allowing an operator to reposition the panel as needed to accommodate different sizes or shapes of material being fed through the feeder slot 904. Alternatively, the inner panel 920 may comprise one or more mechanisms for automatically moving or adjusting its position, such as motorized actuators, spring-loaded assemblies, or other suitable drive systems. These mechanisms may be configured to respond to the presence or dimensions of the sheet 950 to ensuring that the inner panel 920 closely conforms to the sheet 950 and minimizes exposure to the laser or reflections thereof. The coupling of the inner panel 920 to the outer panel 902 or to other structural elements of the apparatus 900 may be achieved using hinges, tracks, sliding rails, pivot points, or other attachment mechanisms, as would be understood by those of ordinary skill in the art, to facilitate smooth movement of the inner panel 920 during operation of the laser machine.

[0075] As illustrated in FIG. 9A, the panel 920 is at least partially opened, revealing a gap 930 between the rollers 910A, 910B, and the sheet 950. As shown in FIG. 9B, the panel 920 is depicted in a closed position such that it makes contact with the sheet 950, effectively concealing the gap 930 that was visible in FIG. 9A. By closing off the gap 930, the panel 920 serves to reduce the likelihood of laser light escaping from the interior of the laser machine through the feeder slot 904. Additionally, this configuration helps to minimize the potential for contaminants, such as dust or fumes generated during the laser cutting process, from exiting the machine and entering the surrounding environment.

[0076] In at least one embodiment, one or more sensors, such as sensors 922A and 922B, may be incorporated within the apparatus 900. As depicted in FIGS. 9A and 9B, these sensors are illustrated with dotted lines to indicate their placement behind the components to which they are mounted. Specifically, the sensor 922A is mounted to the movable inner panel 920, while the sensor 922B is mounted to an interior surface of the outer panel 902. In at least one embodiment, the sensors 922 A and 922B may be positioned adjacent to or along the edges of their respective coupling locations, such as the periphery of the movable inner panel 920 or the interior surface of the outer panel 902, to optimize detection accuracy and coverage.

[0077] FIG. 10 illustrates an apparatus 1000, which represents a variation of the apparatus 900. Each of a plurality of panels 1020A-1020D (four total) are depicted, while an outer panel (e.g., the outer panel 902) is not shown to avoid obscuring the drawing. A plurality of sensors 1022A-1022F are disposed along various edges of the panels 1020A-1020D. As depicted, the apparatus 1000 includes rollers 1010A and 1010B, which are depicted as a series of discrete rollers disposed along central axels 1012A and 1012B, respectively. In such embodiments, the inclusion of additional panels is advantageous for addressing potential gaps that may exist between the sheet 950 and the axels 1012A and 1012B. As illustrated, panels 1020A and 1020B are depicted in a contact position with the sheet 950, effectively blocking gaps along a lateral direction. Panels 1020C and 1020D are shown in their retracted positions, but are configured to move into a closed position such that they both contact opposing surfaces of the sheet 950. In at least one embodiment, the panels 1020C and 1020D may be arranged to cover or overlap panels 1020 A and 1020B when viewed from the outside looking in.

[0078] Any of the sensors shown in FIGS. 9A, 9B, and 10 may be operatively coupled to a processing device or control system within the laser machine, enabling real-time detection of the presence and position of the sheet 950 as it is inserted through the feeder slot. The processing device or control system may be the same as or similar to the computing device 1200 described with respect to FIG. 12. The sensors can be configured to determine whether the sheet 950 is in contact with the protective surfaces of the panels, thereby ensuring that any gaps are concealed before laser operation commences. In at least one embodiment, the processing device may be operatively coupled to the sensors and configured to actuate the one or more panels based on sensor data. In at least one embodiment, the processing device provides safety interlock functionality, such as pausing or disabling the laser if the panels are not in the correct position relative to the sheet 950 or to each other when no material is being loaded. In at least one embodiment, the sensors may be proximity sensors, such as infrared proximity sensors, capacitive sensors, force-sensitive resistors, or a combination thereof, or may be pressure sensors. These various sensor types can be selected and configured based on the specific requirements of the laser machine and the materials being processed.

[0079] In at least one embodiment, the processing device may be operatively coupled to a memory for storing calibration data, which may be an internal memory of the laser machine or may be remotely accessible as would be appreciated by those of ordinary skill in the art. In at least one embodiment, the processing device is configured to automatically adjust the positions of the one or more movable inner panels based on the calibration data, which may include, for example, data relating to the type of material being processed and the thickness of that material, allowing the apparatus 900 to optimize the sealing and alignment of the panels for a wide rangeof materials and use cases. In at least one embodiment, a user interface is provided that is configured to deliver real-time feedback regarding the status of the panels, the alignment of the material, and overall safety compliance. The user interface may further allow a user to specify properties of the material to be processed, such as material type and thickness, and the processing device may be configured to identify and utilize the relevant calibration data based on these user-specified properties. The user interface may be implemented as a panel that, in at least one embodiment, is integrally formed in either the outer panel 902 or at another location on the external housing of the laser machine to provide convenient access and streamlined operation for the user.

[0080] In at least one embodiment, the processing device may implement one or more machine learning models to perform the calibration process and to continuously improve its ability to process certain material types based on a variety of material properties. These properties may be determined from sensor data collected during operation, such as optical, thermal, or mechanical characteristics of the material. In at least one embodiment, the one or more machine learning models are trained to recognize patterns in the sensor data and to correlate these patterns with optimal calibration parameters to allow the apparatus 900 to adaptively refine its calibration routines over time. Exemplary machine learning models that may be useful for this purpose include, but are not limited to, supervised learning models such as support vector machines (SVMs), random forests, and gradient boosting machines, which can be trained on labeled datasets of material properties and corresponding calibration parameters. Deep learning models, such as convolutional neural networks (CNNs) and recurrent neural networks (RNNs), may also be employed to analyze complex sensor data streams and extract relevant features for calibration. In addition, unsupervised learning models, such as clustering algorithms and principal component analysis (PCA), can be utilized to identify novel patterns or groupings in the sensor data that may correspond to previously unencountered material types or conditions. Reinforcement learning approaches may further be implemented to enable the system to iteratively optimize calibration strategies based on real-time feedback and performance outcomes. These models can be deployed individually or in combination, depending on the specific requirements and operational context of the laser machine.

[0081] FIG. 11 illustrates a cross-sectional view components of an exemplary feeder apparatus 1100, in accordance with at least one embodiment. An outer panel 1002 and a feeder slot 1004 are depicted, which may be the same as or similar to the outer panel 1002 and feeder slot 1004 illustrated in FIGS. 9A and 9B. The material sheet 950 is shown being fed through the feeder slot 1004, demonstrating the entry of material into the feeder apparatus 1100 for subsequent processing. As depicted, the feeder apparatus 1100 includes a plurality of rollers,specifically rollers 1110A, 1 HOB, and 11 IOC, which collectively define a feed path for transporting material into the laser machine. Rollers 1110A and 1110B are depicted as passive rollers, positioned respectively above the feed path to guide and support the sheet 950 as it advances toward the laser processing area. Roller 1110C is depicted as an active roller that is motorized and configured to apply a controlled force to the sheet 950. In at least one embodiment, the roller 1110C is coupled to a motorized assembly 1114, which may include components such as pistons, springs, or rubber elements to enable variable force application and positional adjustment. This motorized assembly 1114 may be operatively coupled to a processing device 1130 (which may be the same as or different from the processing device described above for the apparatus 900) that is configured to control the position of the active roller 1110C and adjust the applied force or roller position in response to detected material properties or real-time feedback from the system. It should be understood that the specific locations of passive rollers 1110A and 1 HOB, as well as the active roller 1110C, are provided for illustrative purposes only. In alternative embodiments, the active roller 1110C may be positioned above the sheet 950 rather than below, or additional active and / or passive rollers may be incorporated along the feed path to further enhance material guidance, control, or alignment. The arrangement and number of rollers can be adapted based on the requirements of the material being processed or the desired precision of feeding and alignment.

[0082] In at least one embodiment, a roller platform 1150 is provided external to and separate from the laser machine to facilitate the feeding of elongated materials into the feeder slot 1004. The roller platform 1150 includes a plurality of passive rollers 1152, which are arranged to support and guide the material as it is introduced toward the feed path defined by rollers 1110A, 1110B, and 1110C. To improve the stability of loading the sheet 950, the roller platform 1150 may be configured with an adjustable height feature, allowing the platform to be raised or lowered to align with the feeder slot 1004. Additionally, the roller platform 1150 may be mechanically coupled to the outer panel 1102 of the laser machine via a hinge mechanism 1154.

[0083] In at least one embodiment, the processing device 1130 is further configured to dynamically adjust the spacing between the rollers to accommodate materials of different thicknesses, thereby ensuring optimal engagement and transport of the material through the feeder apparatus 1100. This adjustment may be performed automatically in response to input received from one or more sensors positioned along the feed path. These sensors are capable of detecting various properties of the material to be processed, such as thickness, rigidity, or surface characteristics. The data collected by the sensors is communicated to the processing device 1130, which analyzes the information and selects appropriate operational settings for themotorized rollers. Such settings may include, but are not limited to, the pressure applied by the rollers, the speed at which the rollers advance the material, and other parameters relevant to the safe and efficient handling of the material.

[0084] In at least one embodiment, the feeder apparatus 1100 further comprises a user interface, similar to the one described above, which allows an operator to specify parameters of the material to be processed, such as material type, thickness, length, and rigidity. The user interface may be configured to receive manual input or to display recommended settings based on sensor data to provide the user with greater control and flexibility in configuring the feeder apparatus 1100 for specific materials or processing requirements. In at least one embodiment, the user is provided with the ability to override any automatically determined or recommended settings.

[0085] In at least one embodiment, the feeder apparatus 1100 is designed to accommodate and process materials that are longer than the depth of the laser machine along the loading direction. In at least one embodiment, this capability is achieved with the aid of the roller platform 1150, which supports and guides the extended length of material as it is fed into and through the laser machine, ensuring smooth and continuous operation even with oversized workpieces.

[0086] It should be understood by those of ordinary skill in the art that the various embodiments described herein, including, but not limited to, the cover for protecting components of the laser machine, the frame for supporting components of the laser machine, the safety enhancement apparatus, and the feeder apparatus, are not mutually exclusive and may be combined in any number of ways as appropriate for a given application. Such combinations may be implemented without departing from the spirit or scope of the present disclosure and without loss of functionality. The features and advantages of each embodiment may be realized individually or in combination with one another, and the specific configuration or integration of these embodiments may be tailored to meet the requirements of particular material processing scenarios or operational environments.

[0087] FIG. 12 illustrates a diagrammatic representation of a machine in the example form of a computing device 1200 within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative embodiments, the machine may be connected (e.g., networked) to other machines in a local area network (LAN), an intranet, an extranet, or the Internet. The machine may operate in the capacity of a server or a client machine in a client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The machine may be a personal computer (PC), a tablet computer, a personal digital assistant (PDA), a cellular telephone, a webappliance, a server, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine.Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines (e.g., computers) that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein. In one embodiment, the computing device 1200 corresponds to any of the processing devices or other computerized components of a laser machine described herein.

[0088] The example computing device 1200 includes a processing device 1202, a main memory 1204 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM), etc.), a static memory 1206 (e.g., flash memory, static random access memory (SRAM), etc.), and a secondary memory (e.g., a data storage device 1228), which communicate with each other via a bus 1208.

[0089] Processing device 1202 represents one or more general -purpose processors such as a microprocessor, central processing unit, or the like. More particularly, the processing device 1202 may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processing device 1202 may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. Processing device 1202 is configured to execute the processing logic (instructions 1226) for performing operations and steps discussed herein.

[0090] The computing device 1200 may further include a network interface device 1222 for communicating with a network 1264. The computing device 1200 also may include a video display unit 1210 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 1212 (e.g., a keyboard), a cursor control device 1214 (e.g., a mouse), and a signal generation device 1220 (e.g., a speaker).

[0091] The data storage device 1228 may include a machine-readable storage medium (or more specifically a non-transitory computer-readable storage medium) 1224 on which is stored one or more sets of instructions 3826 embodying any one or more of the methodologies or functions described herein. A non-transitory storage medium refers to a storage medium other than a carrier wave. The instructions 1226 may also reside, completely or at least partially, within the main memory 1204 and / or within the processing device 1202 during execution thereof by the computer device 1200, the main memory 1204 and the processing device 1202 also constituting computer-readable storage media.

[0092] The computer-readable storage medium 1224 may also be used to store instructions for performing the methodologies described herein, calibration data, signal data, materials data, instructions for laser cutting, or other data relevant to the embodiments described herein, as would be appreciated by those of ordinary skill in the art. While the computer-readable storage medium 1224 is shown in an example embodiment to be a single medium, the term “computer- readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and / or associated caches and servers) that store the one or more sets of instructions. The term “computer-readable storage medium” shall also be taken to include any non-transitory medium (e.g., a medium other than a carrier wave) that is capable of storing or encoding a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present disclosure. The term “computer- readable storage medium” shall accordingly be taken to include, but not be limited to, solid-state memories, and optical and magnetic media.

[0093] The following exemplary embodiments are now described.

[0094] Embodiment 1 : A cover adapted for protecting components of a laser machine, the cover comprising: a body having an elongated shape and being adapted to couple to a gantry of a laser machine; and at least one flexible member coupled to an edge of the body, wherein the body, when coupled to the gantry, defines an internal cavity and a channel that spans opposing ends of the body, and wherein the at least one flexible member is adapted to at least partially cover the channel.

[0095] Embodiment 2: The cover of Embodiment 1, wherein the at least one flexible member comprises a rubber material, a way cover, a brush, or a combination thereof.

[0096] Embodiment 3 : The cover of either Embodiment 1 or Embodiment 2, wherein the at least one flexible member comprises: a first flexible member coupled to the body along an edge of the channel, wherein the first flexible member is in contact with a second flexible member coupled to the gantry, and wherein the first flexible member and the second flexible member collectively cover the channel.

[0097] Embodiment 4: The cover of Embodiment 3, wherein the at least one flexible member comprises a third flexible member coupled to a first internal surface of the body within the internal cavity, wherein the third flexible member is oriented parallel to the channel and is positioned to avoid contact with each of the first flexible member and the second flexible member.

[0098] Embodiment 5: The cover of Embodiment 4, wherein an additional flexible member is coupled to an interior surface of the gantry and is oriented parallel to the channel andpositioned to avoid contact with each of the first flexible member and the second flexible member.

[0099] Embodiment 6: The cover of any one of the preceding Embodiments, wherein the body is formed from two separate monolithic pieces.

[0100] Embodiment 7: The cover of any one of the preceding Embodiments, integrated into a laser machine, wherein the laser machine is a laser cutting machine, a computer numerical control (CNC) milling machine, or a three-dimensional (3D) printer machine.

[0101] Embodiment 8: A laser cutting machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; an external housing supported on the frame; a laser apparatus comprising: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry; a laser head moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the laser apparatus to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the motorized longitudinal rail is substantially contained within the internal cavity, and wherein the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

[0102] Embodiment 9: The laser cutting machine of Embodiment 8, wherein the at least one flexible member comprises a first flexible member coupled to the body along an edge of the channel, wherein the gantry comprises a second flexible member coupled to the gantry along an opposing edge of the channel, wherein the first flexible member and the second flexible member are in contact, and wherein laser head deforms and separates the first and second flexible members in the immediate vicinity of the laser head while remaining portions of the first and second flexible members collectively cover the channel.

[0103] Embodiment 10: The laser cutting machine of Embodiment 9, wherein during operation, the first flexible member and the second flexible member prevent or reduce smoke, debris, and / or other particulates from contacting components of the laser apparatus housed within the cover.

[0104] Embodiment 11 : The laser cutting machine of any one of Embodiments 8-10, wherein the gantry further comprises a panel within the internal cavity that is coupled to the longitudinal rail.

[0105] Embodiment 12: The laser cutting machine of any one of Embodiments 8-10, wherein the laser head comprises a flexible ring member.

[0106] Embodiment 13: The laser cutting machine any one of Embodiments 8-10, further comprising at least one lighting element disposed on the body of the cover.

[0107] Embodiment 14: The laser cutting machine any one of Embodiments 8-10, further comprising an exhaust fan adapted for drawing air current through the internal cavity of the cover.

[0108] Embodiment 15: An apparatus comprising: a gantry; a longitudinal rail coupled to the gantry; a laser head moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the gantry to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the longitudinal rail is housed within the internal cavity.

[0109] Embodiment 16: The apparatus of Embodiment 15, wherein the at least one flexible member comprises a first flexible member coupled to the body along an edge of the channel, and wherein the gantry comprises a second flexible member coupled to the gantry along an opposing edge of the channel.

[0110] Embodiment 17: The apparatus of Embodiment 16, wherein the first flexible member and the second flexible member are in contact, and wherein laser head deforms and separates the first and second flexible members in the immediate vicinity of the laser head while remaining portions of the first and second flexible members collectively cover the channel.[oni] Embodiment 18: The apparatus of any one of Embodiments 15-17, wherein the laser head comprises a flexible ring member.

[0112] Embodiment 19: The apparatus of any one of Embodiments 15-18, further comprising at least lighting element disposed on the body of the cover.

[0113] Embodiment 20: The apparatus of any one of Embodiments 15-19, wherein the apparatus is configured for use in a laser cutting machine, a computer numerical control (CNC) milling machine, or a three-dimensional (3D) printer machine.

[0114] Embodiment 21 : A laser cutter frame comprising two sides configured for mounting machine components, the frame providing precise registration features to improve accuracy in component placement.

[0115] Embodiment 22: The laser cutter frame of Embodiment 21, wherein each side is formed as a single unitary part from a rigid material, the single-part construction being achieved by manufacturing processes comprising molding, forging, or CNC milling.

[0116] Embodiment 23: The laser cutter frame of either Embodiment 21 or Embodiment 22, wherein the single-part construction of each side increases the rigidity of the frame to reduce the number of required.

[0117] Embodiment 24: The laser cutter frame of any one of Embodiments 21-23, wherein each side of the frame includes integral features for supporting the Y and Z axes of a laser cutter.

[0118] Embodiment 25: The laser cutter frame of any one of Embodiments 21-24, wherein the two sides of the frame are connected by structural elements selected from the group consisting of profiles, beams, panels, rods, or similar components.

[0119] Embodiment 26: A laser cutter frame comprising two sides, each side having integrated registration features configured to ensure precise alignment of machine components.

[0120] Embodiment 27: A laser cutter frame comprising two sides, each side having a monolithic construction to eliminate the need for additional connecting components and reduce assembly complexity.

[0121] Embodiment 28: The laser cutter frame of Embodiment 27, wherein the monolithic construction of each side comprises a single unitary piece of robust material to improve overall frame rigidity.

[0122] Embodiment 29: A laser cutter frame with two sides, designed to reduce manufacturing and assembly errors by providing a simplified, single-part construction for each side.

[0123] Embodiment 30: A laser cutter frame comprising two sides, each side configured to accommodate components of the X, Y, and Z axes, thereby streamlining machine assembly.

[0124] Embodiment 31 : A frame for CNC machines, comprising two sides configured for mounting machine components and providing precise registration for high accuracy in component placement, wherein the CNC machine is selected from a laser cutter machine, CNC milling machines, and a 3D printer.

[0125] Embodiment 32: A safety enhancement apparatus for a laser machine, the apparatus comprising: an outer panel defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

[0126] Embodiment 33 : The apparatus of Embodiment 32, wherein the one or more movable inner panels are configured to substantially block light generated within the laser machine during operation from exiting through the feeder slot.

[0127] Embodiment 34: The apparatus of either one of Embodiment 32 or Embodiment 33, further comprising one or more proximity sensors integrated into each of the one or more movable inner panels to detect the presence of the material to be processed.

[0128] Embodiment 35: The apparatus of Embodiment 34, wherein the one or more proximity sensors are selected from infrared proximity sensors, capacitive sensors, forcesensitive resistors, or a combination thereof.

[0129] Embodiment 36: The apparatus of Embodiment 34, wherein the one or more proximity sensors are configured to continuously monitor the position of the material, the apparatus further comprising: one or more actuators configured to automatically adjust the positions of the panels in response to data generated by the one or more proximity sensors.

[0130] Embodiment 37: The apparatus of Embodiment 36, wherein the one or more actuators comprise a motor, a spring, or a combination thereof.

[0131] Embodiment 38: The apparatus of any one of Embodiments 32-37, further comprising one or more pressure sensors integrated into each of the one or more movable inner panels to detect the presence and position of the material to be processed.

[0132] Embodiment 39: The apparatus of either one of Embodiment 34 or Embodiment 38, wherein the one or more proximity sensors or the one or more pressure sensors are disposed along edges of their corresponding panel.

[0133] Embodiment 40: The apparatus of either one of Embodiment 34 or Embodiment 38, further comprising: a processing device configured to process sensor data and to cause adjustments to the positions of the one or more movable inner panels.

[0134] Embodiment 41 : The apparatus of any one of Embodiments 32-40, further comprising one or more switches integrated into each of the one or more movable inner panels to detect the presence of the material to be processed.

[0135] Embodiment 42: The apparatus of any one of Embodiments 32-41, wherein the one or more movable inner panels are mounted on adjustable brackets or arms configured to securely clamp around the feeder slot.

[0136] Embodiment 43: The apparatus of any one of Embodiments 32-42, wherein the one or more movable inner panels are configured for manual adjustment to allow a user of the laser machine to align the one or more movable inner panels with the material to be processed.

[0137] Embodiment 44: The apparatus of any one of Embodiments 32-43, further comprising a safety interlock system that prevents the laser machine from operating unless all the one or more movable inner panels have made contact with the material.

[0138] Embodiment 45: The apparatus of any one of Embodiments 32-44, further comprising: a memory for storing calibration data; and a processing device operably coupled to the memory, wherein the processing device is configured to automatically adjust positions of the one or more movable inner panels based on the calibration data.

[0139] Embodiment 46: The apparatus of Embodiment 45, wherein the calibration data comprises one or more of materials type data and thickness data.

[0140] Embodiment 47: The apparatus of Embodiment 45, further comprising: a user interface configured to provide real-time feedback on panel status, material alignment, and safetycompliance, wherein the user interface is further configured to allow for a user to specify properties of the material to be processed, and wherein the processing device is configured to identify relevant calibration data based on the specified properties.

[0141] Embodiment 48: The apparatus of any one of Embodiments 32-47, integrated into the laser cutting machine of any one of Embodiments 8-14.

[0142] Embodiment 49: A laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; a laser apparatus comprising a laser head; a feeder apparatus; a external housing supported on the frame and encompassing the laser apparatus and the feeder apparatus; and a safety enhancement apparatus comprising: an outer panel integrated with the external housing and defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

[0143] Embodiment 50: The laser machine of Embodiment 49, wherein the laser machine is a laser cutting machine, a computer numerical control (CNC) milling machine, or a three- dimensional (3D) printer machine.

[0144] Embodiment 51 : The laser machine of either one of Embodiment 49 or Embodiment 50, further comprising: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry, wherein the laser head a laser head is moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the laser apparatus to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the motorized longitudinal rail is substantially contained within the internal cavity, and wherein the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

[0145] Embodiment 52: A feeder apparatus for a laser machine, the feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized.

[0146] Embodiment 53: The feeder apparatus of Embodiment 52, wherein the motorized roller is configured to adjust a force applied to the material to be processed based on properties of the material.

[0147] Embodiment 54: The feeder apparatus of either one of Embodiment 52 or Embodiment 53, wherein the feeder apparatus is configured to automatically adjust a distance between rollers to accommodate materials of varying thicknesses.

[0148] Embodiment 55: The feeder apparatus of any one of Embodiments 52-54 wherein the feeder apparatus comprises a movable assembly including at least one of pistons, springs, or rubber elements, or a combination thereof configured to apply variable force to the rollers.

[0149] Embodiment 56: The feeder apparatus of any one of Embodiments 52-55, further comprising a processing device configured to adjust the force applied by the one or more motorized rollers.

[0150] Embodiment 57: The feeder apparatus of Embodiment 56, further comprising one or more sensors configured to detect the presence and thickness of the material to be processed as it enters the laser machine, wherein the one or more sensors are operatively coupled to the processing device, and wherein the processing device is configured to detect a type or properties of the material to be processed based at least in part on data generated by the one or more sensors.

[0151] Embodiment 58: The feeder apparatus of either one of Embodiment 56 or Embodiment 57, wherein the processing device is configured to automatically select settings for the one or more motorized rollers for the material to be processed.

[0152] Embodiment 59: The feeder apparatus of any one of Embodiments 52-58, wherein the apparatus is configured to automatically adjust roller speed and pressure based on the type and properties of the material as detected by sensors.

[0153] Embodiment 60: The feeder apparatus of any one of Embodiments 56-59, wherein the processing device is configured to automatically adjust a vertical distance between rollers to accommodate materials of varying thicknesses without manual intervention.

[0154] Embodiment 61 : The feeder apparatus of any one of Embodiments 52-60, further comprising: a user interface configured to allow for a user to specify properties of the material to be processed, and wherein the processing device is configured to identify relevant calibration data based on the specified properties for controlling the one or more motorized rollers.

[0155] Embodiment 62: The feeder apparatus of any one of Embodiments 52-61, wherein the feeder apparatus is configured to process materials longer than a depth of the laser machine along a loading direction, such that a material having a length greater than the depth of the laser machine can be accommodated by sequentially feeding the material through a machining area within the laser machine.

[0156] Embodiment 63: The feeder apparatus of Embodiment 62, wherein the sequential feeding of material is controllable by a processing device that is configured to manage operationone or more of the motorized rollers and adjust their operation based on properties of the material to be processed.

[0157] Embodiment 64: The apparatus of any one of Embodiments 52-63, integrated into the laser cutting machine of any one of Embodiments 8-14.

[0158] Embodiment 65: The apparatus of any one of Embodiments 52-63 integrated with the apparatus of any one of Embodiments 32-47.

[0159] Embodiment 66: A laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; a laser apparatus comprising a laser head; and a feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material.

[0160] Embodiment 67: The laser machine of Embodiment 32, wherein the laser machine is a laser cutting machine, a computer numerical control (CNC) milling machine, or a three- dimensional (3D) printer machine.

[0161] Embodiment 68: The laser machine of Embodiment 32, further comprising: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry, wherein the laser head a laser head is moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the laser apparatus to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the motorized longitudinal rail is substantially contained within the internal cavity, and wherein the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

[0162] Embodiment 69: A method comprising: providing an outer panel defining a feeder slot configured for insertion of a material to be processed; positioning one or more movable inner panels inside the feeder slot, each movable inner panel being adjustable to conform to the shape and / or size of the material; detecting, by one or more sensors, one or more physical parameters of the material; and causing, by a processing device operatively coupled to the sensors and the movable inner panels, the movable inner panels to move and adjust based on data generated by the one or more sensors.

[0163] Embodiment 70: A method comprising: providing a plurality of rollers defining a feed path and configured to transport a material into a laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, at least one of the plurality of rollers is disposed above the feed path, and at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material as determined by one or more sensors; and causing, by a processing device, the rollers to be actuated and adjusted based on data generated by the one or more sensors to conform to the properties of the material.

[0164] In the foregoing description, numerous details are set forth. It will be apparent, however, to one of ordinary skill in the art having the benefit of this disclosure, that the present disclosure may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present disclosure.

[0165] The words “example” or “exemplary” are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the words “example” or “exemplary” is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from context, “X includes A or B” is intended to mean any of the natural inclusive permutations. That is, if X includes A; X includes B; or X includes both A and B, then “X includes A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Reference throughout this specification to “certain embodiments,” “one embodiment,” “at least one embodiment,” or the like means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “certain embodiments,” “one embodiment,” “at least one embodiment,” or the like in various places throughout this specification are not necessarily all referring to the same embodiment.

[0166] The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, while the present disclosure has been described in the context of a particular embodiment in a particularenvironment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein, along with the full scope of equivalents to which such claims are entitled.

Claims

1. What is claimed is:

1. A safety enhancement apparatus for a laser machine, the apparatus comprising: an outer panel defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

2. The apparatus of claim 1, wherein the one or more movable inner panels are configured to substantially block light generated within the laser machine during operation from exiting through the feeder slot.

3. The apparatus of claim 1, further comprising one or more proximity sensors integrated into each of the one or more movable inner panels to detect the presence of the material to be processed.

4. The apparatus of claim 3, wherein the one or more proximity sensors are selected from infrared proximity sensors, capacitive sensors, force-sensitive resistors, or a combination thereof.

5. The apparatus of claim 3, wherein the one or more proximity sensors are configured to continuously monitor the position of the material, the apparatus further comprising: one or more actuators configured to automatically adjust the positions of the panels in response to data generated by the one or more proximity sensors.

6. The apparatus of claim 5, wherein the one or more actuators comprise a motor, a spring, or a combination thereof.

7. The apparatus of claim 1, further comprising one or more pressure sensors integrated into each of the one or more movable inner panels to detect the presence and position of the material to be processed.

8. The apparatus of either one of claim 3 or claim 7, wherein the one or more proximity sensors or the one or more pressure sensors are disposed along edges of their corresponding panel.

9. The apparatus of either one of claim 3 or claim 7, further comprising:a processing device configured to process sensor data and to cause adjustments to the positions of the one or more movable inner panels.

10. The apparatus of claim 1, further comprising one or more switches integrated into each of the one or more movable inner panels to detect the presence of the material to be processed.

11. The apparatus of claim 1, wherein the one or more movable inner panels are mounted on adjustable brackets or arms configured to securely clamp around the feeder slot.

12. The apparatus of claim 1, wherein the one or more movable inner panels are configured for manual adjustment to allow a user of the laser machine to align the one or more movable inner panels with the material to be processed.

13. The apparatus of claim 1, further comprising a safety interlock system that prevents the laser machine from operating unless all the one or more movable inner panels have made contact with the material.

14. The apparatus of claim 1, further comprising: a memory for storing calibration data; and a processing device operably coupled to the memory, wherein the processing device is configured to automatically adjust positions of the one or more movable inner panels based on the calibration data.

15. The apparatus of claim 14, wherein the calibration data comprises one or more of materials type data and thickness data.

16. The apparatus of claim 14, further comprising: a user interface configured to provide real-time feedback on panel status, material alignment, and safety compliance, wherein the user interface is further configured to allow for a user to specify properties of the material to be processed, and wherein the processing device is configured to identify relevant calibration data based on the specified properties.

17. A laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members;a laser apparatus comprising a laser head; a feeder apparatus; a external housing supported on the frame and encompassing the laser apparatus and the feeder apparatus; and a safety enhancement apparatus comprising: an outer panel integrated with the external housing and defining a feeder slot configured for insertion of a material to be processed; and one or more movable inner panels positioned inside the feeder slot, each movable inner panel being adjustable to conform to the shape and size of the material.

18. The laser machine of claim 17, wherein the laser machine is a laser cutting machine, a computer numerical control (CNC) milling machine, or a three-dimensional (3D) printer machine.

19. The laser machine of claim 17, further comprising: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry, wherein the laser head a laser head is moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the laser apparatus to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; and at least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the motorized longitudinal rail is substantially contained within the internal cavity, and wherein the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

20. A feeder apparatus for a laser machine, the feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized.

21. The feeder apparatus of claim 20, wherein the motorized roller is configured to adjust a force applied to the material to be processed based on properties of the material.

22. The feeder apparatus of claim 20, wherein the feeder apparatus is configured to automatically adjust a distance between rollers to accommodate materials of varying thicknesses.

23. The feeder apparatus of claim 22, wherein the feeder apparatus comprises a movable assembly including at least one of pistons, springs, or rubber elements, or a combination thereof configured to apply variable force to the rollers.

24. The feeder apparatus of claim 21, further comprising a processing device configured to adjust the force applied by the one or more motorized rollers.

25. The feeder apparatus of claim 24, further comprising one or more sensors configured to detect the presence and thickness of the material to be processed as it enters the laser machine, wherein the one or more sensors are operatively coupled to the processing device, and wherein the processing device is configured to detect a type or properties of the material to be processed based at least in part on data generated by the one or more sensors.

26. The feeder apparatus of claim 24, wherein the processing device is configured to automatically select settings for the one or more motorized rollers for the material to be processed.

27. The feeder apparatus of claim 25, wherein the apparatus is configured to automatically adjust roller speed and pressure based on the type and properties of the material as detected by sensors.

28. The feeder apparatus of claim 24, wherein the processing device is configured to automatically adjust a vertical distance between rollers to accommodate materials of varying thicknesses without manual intervention.

29. The feeder apparatus of claim 20, further comprising: a user interface configured to allow for a user to specify properties of the material to be processed, and wherein the processing device is configured to identify relevant calibration data based on the specified properties for controlling the one or more motorized rollers.

30. The feeder apparatus of claim 20, wherein the feeder apparatus is configured to process materials longer than a depth of the laser machine along a loading direction, such that a material having a length greater than the depth of the laser machine can be accommodated by sequentially feeding the material through a machining area within the laser machine.

31. The feeder apparatus of claim 30, wherein the sequential feeding of material is controllable by a processing device that is configured to manage operation one or more of the motorized rollers and adjust their operation based on properties of the material to be processed.

32. A laser machine comprising: a frame comprising opposing sides coupled together by a plurality of rigid structural members; a laser apparatus comprising a laser head; and a feeder apparatus comprising: a plurality of rollers defining a feed path and configured to transport a material into the laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, wherein at least one of the plurality of rollers is disposed above the feed path, and wherein at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material.

33. The laser machine of claim 32, wherein the laser machine is a laser cutting machine, a computer numerical control (CNC) milling machine, or a three-dimensional (3D) printer machine.

34. The laser machine of claim 32, further comprising: a gantry moveably coupled to motorized transverse rails at opposing ends of the gantry, the motorized transverse rails being coupled to the opposing sides of the frame; a motorized longitudinal rail coupled to the gantry, wherein the laser head a laser head is moveably coupled to and constrained to move along the longitudinal rail; and a cover coupled to the laser apparatus to define an internal cavity and a channel, the cover comprising: a body having an elongated shape; andat least one flexible member coupled to the body, wherein the at least one flexible member is adapted to at least partially cover the channel, wherein the motorized longitudinal rail is substantially contained within the internal cavity, and wherein the laser head at least partially extends out of the internal cavity and past the at least one flexible member.

35. A method compri sing : providing an outer panel defining a feeder slot configured for insertion of a material to be processed; positioning one or more movable inner panels inside the feeder slot, each movable inner panel being adjustable to conform to the shape and / or size of the material; detecting, by one or more sensors, one or more physical parameters of the material; and causing, by a processing device operatively coupled to the sensors and the movable inner panels, the movable inner panels to move and adjust based on data generated by the one or more sensors.

36. A method comprising: providing a plurality of rollers defining a feed path and configured to transport a material into a laser machine for processing via a feeder slot, wherein at least one of the plurality of rollers is disposed below the feed path, at least one of the plurality of rollers is disposed above the feed path, and at least one of the plurality of rollers is motorized and configured to adjust a force applied to the material to be processed based on properties of the material as determined by one or more sensors; and causing, by a processing device, the rollers to be actuated and adjusted based on data generated by the one or more sensors to conform to the properties of the material.

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