Creality Falcon 2 Pro 40W Laser Review

Jul 12, 2024

Aurora Tech Channel - Creality Falcon 2 Pro 40W Laser Review

Overview

  • Product: Creality Falcon 2 Pro 40W Laser Module (fully enclosed version)
  • Working Area: 400x415 mm
  • Weight: ~18.5 kg (40 lb)
  • Motion System: Palm wheels on X & Y axis, dual limit switches, adjustable belt tension
  • Z Axis: Thumb screw & 3-step gauge for focal length adjustment
  • Bed Style: Grill style bed (vertical for cutting, flat for engraving)
  • Price: $1,659 (enclosure and other accessories included)

Key Features

  • Frame: Custom rigid aluminum frame
  • Electronic Enclosure: Front-mounted with controller board and standard ports, includes safety features (emergency stop, safety lock, automatic/manual LED light & exhaust fan)
  • Laser Module: 40W module (high power, suitable for cutting but not fine engraving), also includes a 1.6W module for detailed photo engraving
  • Air Assist Pump: Integrated control via G-code, automatic airflow detection, flame sensor, and lens cleaning sensor
  • Enclosure: Metal tray, acrylic panels, riser base, grill working bed
  • Bundle: Currently includes an Ender 3 V3 3D printer

Assembly

  1. **Components Included: **Metal tray, laser modules, ducting, air pump, power supply, accessories
  2. Assembly: Semi-assembled; only frame and belts pre-installed; must assemble top cover frame, slide panels, and secure with screws.
  3. External Components: Connect air pump, power supply, USB cables (incl. webcam).
  4. Setup: Unlock, home the machine, set exhaust fan to auto, configure in LightBurn software.

Engraving & Cutting Tests

Simple Engraving Test (2mm Plywood)

  • Settings: Speed: 13,000 to 20,000 mm/min, varied power levels.
  • Results: Minor differences between speeds due to small engraving area.

Cutting Test

  • 2mm Plywood: Settings from 600 to 1200 mm/min, 100% power achieves clean cuts around 800-1000 mm/min.
  • 5mm Plywood: Best results at ≤900 mm/min.
  • 12.7mm Poplar Wood: Clean cuts at 100-150 mm/min.
  • 19mm Woodboard: Clean cuts at 100-150 mm/min, fails at higher speeds.

Photo Engraving Test

  • 40W Module: Not suitable for high detail; best results at 10,000 mm/min, 20% power.
  • 1.6W Module: Best for photo engraving; detailed at 2,000 mm/min, takes the longest time.
  • Precision Mode: Improved results but 1.6W module still superior.

Acrylic Cutting Test

  • Settings: 100-800 mm/min, 100% power.
  • Results: Clean cuts up to 600 mm/min, rough edges; better results at 50% power.

Camera Setup & Alignment

  • Camera Position: Fixed at the top, wide angle, detected as standard lens.
  • Calibration: Using alignment card, engraves patterns, adjust offset.
  • Accuracy: Acceptable within <1mm; better than preview frame method.
  • Real-life Accuracy: Acceptable for aligning logos and patterns.

Pros & Cons

Pros

  1. Powerful Cutting: 40W laser module can cut thick wood quickly.
  2. Air Assist Pump Control: Integrated and controlled via G-code.
  3. Excellent Cable Management: Organized with metal clips.
  4. Safety Features: Comprehensive, includes emergency stop, lock, sensors.
  5. Fixed Camera: Reduces recalibration needs.
  6. Compact Enclosure: Saves space with functional sliding panels.

Cons

  1. Camera as Webcam: Limited accuracy, needs USB connection.
  2. Black-painted Metal Tray: Susceptible to marking and becoming messy.
  3. Palm Wheels for Motion: Less stable at high speeds compared to steel wheels or linear rails.
  4. Inaccurate Parameter Table: Suggested settings from Creality often ineffective.

Conclusion

  • Recommendation: Suitable for users looking for a comprehensive and powerful cutter, particularly those upgrading from less powerful open-frame models. While lacking in some minor areas (like control software), the Falcon 2 Pro 40W presents good value with high build quality and detailed focus on user experience.