As someone who regularly works with CNC and laser machines, I’m always looking for ways to expand my equipment’s capabilities. Recently, I wanted to work on larger projects with my Creality Falcon Pro 10W, but the standard engraving area limited what I could do. After researching solutions, I chose the SCULPFUN S9 engraving area expansion kit. Here’s a detailed account of the upgrade process, the challenges I faced, and the results.
Why I Needed an Upgrade
The Falcon Pro 10W is a reliable and precise laser, perfect for small to medium projects. However, larger workpieces required me to reposition them multiple times or divide designs into sections — a time-consuming process prone to alignment errors.
I wanted a solution that would allow me to:
- Engrave larger projects in a single pass
- Maintain the Falcon Pro’s precision across a bigger area
- Keep the machine stable and rigid after the upgrade
The SCULPFUN expansion kit seemed like the ideal choice, offering a significant increase in engraving area without major modifications.
What the SCULPFUN Expansion Kit Includes
The kit is designed to expand the working area of compatible laser engravers, including the Falcon Pro 10W, and consists of:
- A replacement frame for the Falcon Pro, engineered for the larger working area
- Longer wires and extension cables for motor connections
- Belts and screws required for assembly
- Installation instructions
Unlike some kits, this is not a set of shafts, but a fully engineered frame that replaces the original structure. This ensures the machine remains rigid while providing a larger workspace.
[Insert image: SCULPFUN kit unboxed]
Installing the Replacement Frame
The installation process was straightforward because the SCULPFUN frame is a direct replacement for the Falcon Pro 10W frame. I removed the original frame and mounted the new, longer frame included in the kit. The mounting points aligned perfectly, so no drilling, cutting, or adapter plates were necessary.
Next, I installed the belts included in the kit and replaced the motor cables with the longer extension cables. The cables reached the motors comfortably and allowed full movement across the expanded area.
[Insert image: Installing the SCULPFUN replacement frame]
Limit Switch Wiring Challenge
The SCULPFUN kit comes with extension cables for the motors, but it does not include wiring for the limit switches. Limit switches are essential for:
- Preventing the laser head from crashing into the frame
- Enabling accurate homing and repeatable positioning
- Maintaining safety during operation
Because of this, I had to create custom wiring for the limit switches. This involved measuring, splicing, and insulating wires to connect the X and Y limit switches to the controller. Once complete, the limit switches worked perfectly across the expanded area.
[Insert image: Custom limit switch wiring]
Testing the Expanded Workspace
After installation and wiring, I powered on the Falcon Pro 10W and ran a homing procedure. The laser head moved smoothly across the full 410 × 950 mm area, stopping accurately at the limit switches.
I started with a small test engraving to check precision. The results were excellent: the laser maintained sharp, consistent lines across the entire expanded workspace. The frame remained rigid and stable, proving that the direct replacement design preserves the machine’s original accuracy.
[Insert image: Test engraving on expanded area]
Benefits of the Upgrade
Using the Falcon Pro 10W with the SCULPFUN expansion kit has several advantages:
- Direct replacement frame – No adapters or modifications needed. It installs easily and maintains stability.
- Larger work area – Full 410 × 950 mm workspace allows single-pass engraving for larger projects.
- Maintained precision – The replacement frame is engineered to keep the machine rigid and accurate.
- Improved workflow – Larger pieces can be engraved without repositioning, saving time.
- Expanded creativity – I can now take on bigger and more ambitious projects that were impossible with the original area.
Tips for a Smooth Upgrade
- Prepare for limit switch wiring – The kit doesn’t include these connections, so have extra wires and connectors ready.
- Check belt tension – Proper tension is critical for precision; adjust carefully.
- Start with test engravings – Verify accuracy and homing before moving to full-size projects.
- Follow the instructions – The SCULPFUN manual provides helpful guidance on assembly and cable routing.
Conclusion
Upgrading my Creality Falcon Pro 10W with the SCULPFUN engraving area expansion kit has significantly increased my productivity and creative possibilities. The replacement frame is a true direct swap for the original Falcon Pro frame, making installation simple and maintaining the machine’s rigidity and precision.
While I had to fabricate wiring for the limit switches, the overall upgrade process was straightforward. Now, with a 410 × 950 mm workspace, I can handle larger projects in a single pass and take on more ambitious designs than ever before.
[Insert image: Large finished engraving using expanded Falcon Pro]