NOTICE

The parts and installation techniques shown for the second airline are specific to Thunder Laser Nova Series with V.63 and up firmware and dual-stage air-assist. 

You do NOT have to run an additional airline, you can simply connect the airline going to the stock head if you like.

General Overview

I have added a LightObject  Laser Engraving Air Assisted Enhancer (long tip) 21mm Kit to my Nova 35-80. I have also modified the dual-stage air-assist plumbing to allow the stock nozzle to receive high stage air while the enhancer receives the low stage air. 

The air pressure monitor was left on the high stage side since low stage air adjustment is tuned by feel, sound, resultant output, etc... but i will probably add a second pressure monitor to the low side at some point.

I will be evaluating the enhancer (and if its worth replumbing the dual air assist, etc...) and will update this article as time permits. more to come!

Nozzle Placement

This is feedback from another Thunder user. Be sure to check clearances when fitting the device. having the air blow directly to the rear is preferable (leave a little gap in the back for the smoke to go through the honeycomb) but that may have to be altered so the nozzle doesn't contact anything.

Parts Used

Enhancer Kit

Laser Engraving Air Assisted Enhancer (long tip) with 21mm diameter LINKED HERE. Use code THUNDER at checkout for 5% off :

Airline Parts

Here is a good assortment that should have what you need to install the second airline if you wish.

https://www.amazon.com/gp/product/B07RJ1BYKV

Secondary Airline Installation

Take lots of pictures and tag/mark the plumbing before changes to the air- assist system.

Here is the Dual Air Assist Theory of Operation and Schematics for your reference.

Overview

Enhancer Nozzle Modification

The imagery from the OEM site shows the tip of the nozzle to be crimped:

Mine arrived with a perfectly round orifice, which is good so i can fashion the nozzle whoever I wish. 

My end goal is to crimp the end of the tip so it will fan the air into a curtain which should mitigate any smoke trying to enter the orifice of the conical nozzle.  Kind of like those blowers at convenience store when the door opens. They keep the conditioned air in and the bugs out. I figure it should work horizontally too.

And you can increase pressures when the air curtain parallels the surface of the work without blowing crap everywhere. Blowing air down into an engraving is like stomping in a mud puddle. This nozzle should mitigate that a lot.

First Acrylic Test

For this test, I left the enhancer orifice unmodified. I also adjusted my low and high stage air to max to eliminate difference in the needle valves as a variable. A static pressure of 1psi (when delivered via the stock nozzle with 2mm orifice) at the secondary regulator so both nozzles will receive the same pressure and volume of air (mostly). 

Running The Experiment

There are no finished results in this video but it describes the setup and controls for the experiment, then records almost to the end of the job. Resultant output is shown in the next section.

Results Before Cleaning

At first glance, there is noticeably less residue on the LO enhancer example and it is all being directed to the rear but the contrast looks far less white and 'chalky'.

Results After Cleaning

I used only room temp tap water and my hand to clean the test piece.

Conclusion

The results of the acrylic test show that the residue is mitigated much better with the LO enhancer and cleanup easier. the reside that was left behind rinsed off. i had to 'scrub' the side with the stock nozzle with my hand a bit to release some stubborn remnants. At the end of the day, there was no perceivable difference in contrast after cleaning.