Chris’s DIY Laser Filter System: Photos, Parts and Airflow

Chris of Make It With Chris built this DIY laser filter system around a tall cabinet with stacked horizontal filter elements and a duct connection at the top. This feature takes a closer look at his actual cabinet, removable granular-media cassette and filter stack, alongside his original supplies list and practical extraction-safety considerations.

Build and photo credit: Chris, Make It With Chris.

You can watch Chris’s DIY laser filter video on TikTok for the original walkthrough. The video link is included here as a companion to the build.

How the air moves through Chris’s system

The airflow runs from the bottom of the cabinet to the top: MERV 8, MERV 11, large charcoal, HEPA and small charcoal, in the order Chris described. Exhaust from the laser enters through a round connection in the rear wall of the bottom chamber, moves upward through the stacked filter elements, and leaves through the top duct. From there, it is routed outdoors through a door, window or garage opening.

Outdoor discharge is part of this setup. Its placement still matters: exhausted air should not be drawn back into occupied spaces through nearby openings or air intakes, including those serving neighboring areas. HSE’s ventilation guidance explains the need to avoid re-entry. Have the discharge arrangement checked for the actual building and local requirements.

A closer look at Chris’s actual filter cabinet

The full-cabinet photo shows a black flexible duct attached to a round flange on the top panel, with a metal band clamp around the connection. Directly beneath that panel is a black cylindrical fan housing. The access side is open, exposing the horizontal stages and the lower inlet chamber. An additional close-up shows the round inlet in the back wall of that chamber.

Chris identifies the five stages in this bottom-to-top airflow order:

1. MERV 8: the lower white element marked “AIR FLOW.”
2. MERV 11: the green-edged Filterbuy element above it.
3. Large charcoal stage: the clear-sided cassette containing dark granules.
4. HEPA: the deeper pleated element in a white frame.
5. Small charcoal stage: the upper stage with the green grid-faced surface beneath the fan housing.

These are Chris’s descriptions of his installed stages. The MERV and HEPA names are not independent test results or certification of the assembled system. “Large” and “small” distinguish the two charcoal stages; they do not specify a measured media quantity or bed depth. The cylindrical fan housing is above the stack, beneath the top duct connection.

The stacked filter section

The green MERV 11 stage, as identified by Chris, has a printed Filterbuy 16×18×1 label that is useful when looking at the build. Another close-up shows the bottom white element printed “MERV 8” and “16×19×1.” These are nominal product-size labels, not measurements of the cabinet. The different printed sizes are a reason to verify each replacement separately instead of assuming the whole stack takes one common size. The close-up also shows dark strips along the stage edges. Their presence in a photo cannot establish how well the assembled cabinet seals.

The “AIR FLOW” marking on the lower white element is a reminder to check each component against its own installation instructions. The airflow through Chris’s cabinet is upward, but a photo alone cannot establish that every element is correctly oriented or sealed. Those details belong in the installation check.

The removable large charcoal cassette

This separate photo shows the cassette that Chris identifies as the large charcoal stage, held outside the cabinet. You can see its clear side, the dark granules inside, and the mesh under the grid-pattern panel. It documents the physical construction detail without establishing the media’s chemical grade, fill weight, bed depth or working capacity.

For anyone comparing this approach with a ready-made extractor, access is worth considering alongside the parts cost. A cassette can be visible and removable while the complete installation still needs its sealing, structural support and contamination-control procedures checked. Do not infer a measured service life or safe media-handling method from the photo.

The parts listed for Chris’s DIY laser filter system

These links come from the DIY filtration section at the bottom of the Make It With Chris Tools and Machines page. They are the original links, so you can find the same listings from one place.

Affiliate disclosure: the parts links below are Chris’s affiliate links. Chris may earn a commission if you buy through them.

The names above identify the supplies on Chris’s list. They do not establish a tested filter rating for the assembled box, a specific fan operating point or a complete bill of materials. Check the selected variation and current specifications on each listing before buying. The route is bottom-in and top-out; the exact flange sizes at each connection should still be checked against the actual installation.

Understand the different jobs inside a filtration system

It helps to separate particle capture, gas treatment and airflow. Each needs to be addressed. Buying a finer filter does not answer the airflow question, and adding activated carbon does not turn a particle-filter assembly into a verified all-purpose fume extractor.

Particle filters

MERV describes particle-filter performance across specified particle-size ranges. It does not measure gas removal. Chris identifies the first two stages in the airflow path as MERV 8 and MERV 11, with the HEPA stage after the large charcoal stage. His supply list links those filter types. A component’s label should not be converted into a whole-system efficiency claim: the filter’s construction, fit and air leaking around it all matter. EPA discusses these distinctions in its technical summary of air cleaners.

In a multi-stage design, the purpose of a prefilter is to reduce the particle load reaching later stages. Donaldson BOFA describes the roles of prefilters and filter-condition monitoring in its extraction systems. Chris’s chosen sequence places the MERV 8 and MERV 11 stages before the large charcoal cassette. That layout and the owner-supplied labels do not establish the performance of any individual stage or the whole assembly. No “99.97%” removal claim is made for this DIY assembly.

Activated carbon

Chris describes two charcoal stages: the large stage between MERV 11 and HEPA, and a smaller stage above HEPA before the fan. Their sizes, grades and quantities are not specified in this article.

Activated carbon is a sorbent: it can capture certain gases and vapors on its surface. Its usefulness depends on the contaminant and the media. Capacity is finite, so the presence of carbon does not establish protection against every gas or prove that the media is still effective. EPA explains that sorbents differ in their affinity for different chemicals and need replacement or regeneration when their useful capacity is exhausted. Its residential-air-cleaner guidance explains the principle; it does not validate this laser build.

HSE’s local exhaust ventilation guide describes particle removal ahead of carbon as a common arrangement. It also warns about sudden loss of performance when carbon becomes saturated and about potential hot spots. A replacement decision needs more than a sniff test. A filter can be unsuitable or exhausted without giving you a dependable odor warning.

The fan, ductwork and housing

The fan has to move air through the resistance of the installed system. Filters, duct runs, bends and connections are part of that system. A fan’s headline airflow figure is not a measurement of how much air reaches the laser with all of those components connected.

Housing seals matter too. A filter can only treat the air that actually passes through its media. Gaps around a filter or access panel can create bypass paths. The assembled system therefore needs checking as a complete installation rather than being judged from a shopping list.

Airflow checks matter more than a strong breeze

A hand held near an opening is not a reliable way to establish adequate extraction. HSE recommends a suitable airflow indicator, with the reading tied to the system’s required performance. In an appropriate simple system, pressure measurement across the filter can also provide useful information. The indicator and its acceptable range should be selected for the installation. See HSE’s airflow guidance.

For a DIY setup, useful commissioning questions include:

• What airflow and pressure does the laser manufacturer require at the machine?
• What does the installed system deliver with the complete filter set in place?
• How will the operator know when resistance has increased enough to reduce extraction below the required level?
• Are there leaks, loose connections, damaged filters or air paths that bypass the media?
• Does the final discharge arrangement prevent contaminated air from returning to occupied areas?

These are checks for a competent ventilation professional to help resolve. They should not be read as measurements already established for Chris’s build. HSE’s commissioning guidance explains why initial airflow and pressure measurements should be recorded as a baseline for later comparisons.

Duct connections and installation details to verify

The supply list contains both 6-inch and 8-inch flanges and an 8-inch duct. In Chris’s system, the laser connection feeds the bottom and the top duct carries air toward the outdoor opening. The overview photo shows the top flange and clamp, but it does not establish every fitting along the run. Before copying it, verify your machine port, connection sizes, filter openings and discharge location. Do not infer a reducer arrangement or cabinet cutout dimensions from the parts list.

Duct material deserves particular attention. Epilog’s exhaust setup guidance specifies rigid or flexible metal ducting for its lasers and warns against potentially flammable soft ducting unless supplied as appropriate fire-proof ducting by the filtration-system manufacturer. It also advises keeping flexible runs short to limit flow losses. Follow the requirements for your own laser and extraction equipment rather than treating a linked duct as automatically suitable.

Plan access for inspection and replacement. The space needed to pull out a filter, reach a clamp or check a seal is part of the installation. A box that fits under a bench still needs enough working clearance to service it safely.

A maintenance plan for this type of setup

The checklist below is a proposed way to organize maintenance. It is not a claim about Chris’s current service schedule or a promise that a filter lasts a particular number of hours. Set inspection and replacement criteria using the component instructions, the materials processed and the measured behavior of the installed system.

Before running the laser

• Confirm the extraction system is operating and its performance indicator is within the established acceptable range.
• Check accessible hoses, clamps, panels and seals for damage or loose connections.
• Make sure the intended filters are present, correctly seated and installed in their specified direction.
• Stop if extraction is malfunctioning or smoke escapes into the workspace. Investigate before continuing.

During scheduled service

• Inspect the filters and replace them according to the established criteria and their manufacturer’s instructions.
• Check for deposits or obstructions in accessible ductwork and the fan. Use the equipment manufacturer’s maintenance method.
• Inspect the housing and seals each time a filter is changed, then verify performance with the system reassembled.
• Use a carbon replacement plan appropriate to the media and contaminants. Do not wait for odor as the only trigger.
• Follow appropriate handling and disposal requirements for contaminated filters and media.

Keep a simple service log: date, material processed, approximate runtime, indicator readings, filter changes, defects found and corrective work. This is a practical application of HSE’s recommendation to maintain operating instructions, records and repairs for extraction systems. See its guidance for LEV owners.

Residue also needs attention outside the filters. Epilog explains that cleaning laser equipment helps reduce flare-ups and that exhaust-unit maintenance should follow the unit manufacturer’s instructions. Its cleaning guidance is a useful reminder to maintain the whole extraction path. It is not a replacement schedule for these DIY components.

Material and fire safety still come first

Do not use this build as a reason to laser PVC, vinyl containing PVC or an unknown material. OMTech’s CO2 cabinet-laser safety guidance prohibits PVC and other halogen-containing materials and tells operators to investigate uncertain materials through their safety documentation or manufacturer support. Verify coatings, adhesives and composite ingredients as well as the base material.

OMTech also instructs operators to stop when extraction malfunctions, keep safety features intact and never leave an operating laser unattended. A DIY filter box does not remove those responsibilities. It also does not replace a suitable fire-response plan, safe electrical installation or the laser’s required protective measures.

The route Chris described sends the exhaust outdoors. Any proposed indoor recirculation would need its own assessment. The fact that a commercial laser extractor may be designed for a particular indoor application does not establish that a homemade assembly has equivalent containment, filtration or monitoring. Chris’s parts list does not include evidence demonstrating that this system’s discharged air is safe to breathe.

Budgeting for a DIY filter system

A useful budget includes more than the fan and first set of filters. List the housing materials, media, supports, gaskets, fittings, ductwork, mounting hardware, any necessary electrical work, testing and replacement consumables. Keep quantity, unit cost and purchase date beside each line.

The linked supplies list does not provide a verified all-in build cost. No total or savings estimate is given here. The linked listings may also contain multiple sizes or pack quantities. Check the actual configuration before comparing prices.

The practical tradeoff is ongoing responsibility. A DIY design gives you control over the component selection and service access, but you still need evidence that the pieces work together for your application. Commercial equipment is worth comparing on documented operating limits, filter availability, monitoring, support and suitability for the materials you process, not just the purchase price.

Use the parts list as a starting point

The links above make the supplies behind Chris’s DIY laser filter project easier to find. Use them alongside the original video walkthrough, the component instructions and the requirements for your specific laser. The airflow route is bottom-in, upward through the cabinet and out the top to outdoors. Before reproducing the build, verify the exact components and have the complete extraction system checked for its intended use.