A Laser Piano Roll Cutter for Home Use

I have spent too much time developing a laser piano roll cutting
machine. I have always wanted one but it is now that I do not have
any roll playing machines that I have decided to do what I wanted
to do for many years. I have written to the MMD about this in the
recent past but now what might have been "vapor ware" is reality.

Of course there may still be bugs in the MIDI to G-code software
and features to be added but at this point it appears to me that it
is actually possible to buy an inexpensive laser engraving machine
and to produce rolls both from scans and from original works
including those produced by A2M [audio to MIDI] conversion of
audio files. This is another project of mine and I have tools
I have shared to help with these conversions.

I have built two machines so far and am working on the latest
which Is a "drop in" adapter that will work with virtually any
laser engraving machine of the consumer type. These machines are
quite common now and the ones I have are some of my favorite toys.

To be able to buy a cheap drawing on Etsy or to spend a few minutes
to hours drawing files in a CAD program and to be able to cut parts
out of plywood or other materials is simply amazing. I have a
$12,000 waterjet machine and my simple laser engravers give me twenty
times the pleasure.

My first attempts (fully realized) required that one use a laser
engraver for parts to make a dedicated piano roll cutting machine.
The new approach allows you to leave your engraver intact and to make
piano rolls with it with simple modifications and a minimum of effort
in construction.

All of the parts needed for the new machine are readily available or
can be custom made using just a laser engraver. Virtually everything
can be made with the laser and hand tools. Although I have many
machines the goal was to be able to make such a machine with just
simple hand tools. A table saw and drill press will make the
construction easier but are not required.

The manual linked below explains both the construction of the
original machine (which still would be best for more than occasional
roll production) and also has a picture of the new design and of the
new laser cut parts. You will need to scroll toward the end of the
manual to find the pictures. Eventually I hope to find time to make
a separate manual for the new "drop in" adapter design.

My goal is to share the plans as well as various programs necessary
to make your own cutter. The only thing I plan to charge money for
is the program to make the necessary G-code files.

I Will be putting together a package that includes all the
documentation and a demo version of the G-code generating program.
It is fully functional but the files it produces will be crippled
in a way that allows the verification of their accuracy but which
includes distortions to prevent the use for actual roll cutting.
I have put a lot of effort into this project and I need to protect
my investment.

My current dedicated machine produces a typical reproducing roll with
expression codes in the margins at about 8 feet per hour. I have not
tested it yet but I think that my (more expensive) 30-watt engraver
with the "drop in" will be considerably faster -- possibly two or
three times as fast.

You can download the "working" version of the manual from this link:
https://docs.google.com/document/d/1ZNrrexTI_8cstw1zzNcLqAgj55yPL3-G/edit 

This is a very long doc with full explanation as to how to build the
original dedicated roll cutting machine. If you do not plan to build
this machine most of the "manual" is not very interesting. I suggest
downloading the manual (when Google previews the manual click "file"
and then "download" to get the manual) for offline viewing where it is
easier to skim and find just the pictures you might be interested in.

I am more likely to provide full documentation on building the
"drop in" version if there seems to be a lot of interest.

Contact me through my email address attached to this post (take off
the ".geentroep" stuff of course) or through the mail contact on my
web site: http://www.spencerserolls.com/ 

Spencer Chase
Garberville, California
http://www.spencerserolls.com/ 
spencer@spencerserolls.com.geentroep [delete ".geentroep" to reply]