Laser Cutting: The Ultimate Guide

Laser cutting is a highly precise and versatile method of cutting various materials. It is widely used in industries such as manufacturing, aerospace, and automotive, as well as in DIY projects. 

In this blog post, we will explore laser cutting, including how it works, the types of materials it can cut, its applications, and advantages. We will also share some tips for getting started with laser cutting.

How Does Laser Cutting Work?

Laser cutting process is directed by computer numerical control (CNC), which makes the process also known as CNC laser cutting. The laser cutter software moves the laser head/module according to the design file and machine settings provided.

When the laser beam lands on the material, the temperature of the material increases within milliseconds, causing sublimation, a process in which a material changes from a solid to a gaseous state without passing through the liquid state. 

The material then vaporizes, and the laser beam penetrates the object to cut it into the desired shape. The process can be completed in one pass if the laser is powerful enough; otherwise, several passes are needed.

Advantages of Laser Cutting

As explained above, laser cutting uses a high-powered laser beam to cut various materials and is directed by computer numerical control software, which achieve numerous advantages over traditional cutting methods.

High-qualtiy Resutls

The highly-powered and focused laser beam produces a very narrow kerf (cutting width) that vaporizes the material being cut, resulting in minimal material waste and producing a clean and smooth edge.

Additionally, laser cutting is a non-contact process, which means there is little risk of deformation or damage to the material.

Automatically and Quickly

Laser cutting is an automated process. After you upload the design to the laser cutter software and adjust the optimal power, speed and focus settings based on the material being cut, guided by the software, the laser beam moves quickly and efficiently.

Incredibly Versatile

Other methods cannot act on a very small area like a laser beam, resulting in wide cuts, large heat-affected zones, and significant workpiece deformation. In addition, laser can cut non-metallic materials, while other thermal cutting methods cannot.  Besides, the laser beam can be adjusted to suit different thicknesses, making it a flexible process that can be used for a variety of applications. 

Additionally, laser cutters can also be used for engraving.

This versatility makes laser cutting a popular choice in many industries. You can even start a business with laser cutting.

Types of Laser Cutting Machines

Understanding the types of laser cutters is crucial because each type is suitable for specific materials. 

CO2 Laser Cutting Machines

In a CO2 laser cutter, the laser beam is produced inside a sealed gas tube that contains a mixture of gas. The higher proportion of the gas is CO2. 

It is ideal for cutting and engraving non-metals, such as wood, leather, plastic, paper, and fabric.

Fiber Laser Cutting Machines

Fiber laser cutting machines are more powerful than CO2 lasers. They cut materials at a fater speed and can cut metals.

Diode Laser Cutting Machines

Diode laser cutters are quite popular and widely used for DIY projects. They are excellent for cutting and engraving wood, opaque acrylic, leather, rubber, fabric, etc. They are more affordable than the other two types of lasers, which is why they are quite common and preferred for crafting and small businesses.

What Materials Can a Laser Cutter Cut?

Laser cutting is a popular technique for cutting various materials, such as wood, acrylic, metal, leather, and more. However, not all materials are suitable for laser cutting, and some may require specific types of laser cutting machines. Here are some materials that are suitable for laser cutting:

1. Wood: Laser cutting is an excellent technique for cutting wood, including plywood, MDF, and solid wood. With a laser cutter, you can create intricate designs, patterns, and shapes with precision and speed. Wood laser engraving is also possible with a laser, allowing for custom decor and personalizd gifts.

RELATED: The ultimate guide on laser cutting wood

2. Acrylic: Acrylic is a popular material for laser cutting due to its versatility, durability, and aesthetic appeal, making it a popular choice for applications that require an attractive and aesthetically pleasing finish, such as awards, trophies, sinage, display, and decorative items.

RELATED: The ultimate guide on laser cutting acrylic

3. Leather: Laser cutting can produce intricate and precise designs on leather with minimal waste. It is commonly used in the fashion industry for cutting leather patches, bags, and accessories.

RELATED: The ultimate guide on laser cutting leather

4. Plastic: Laser cutting is suitable for various plastic materials, including acrylic (PMMA), polystyrene (PS), polyethylene (PE), polypropylene (PP), etc. It is essential to note that different types of plastic react differently to laser cutting. Therefore, it is essential to consult with the laser cutting machine's manufacturer to ensure the plastic material is suitable for laser cutting. Additionally, it is crucial to take precautions when laser cutting plastics as they can release harmful fumes when exposed to high temperatures.

5. Paper and cardboard: Laser cutting is perfect for creating paper and cardboard prototypes, pop-up cards, invitation cards and decorative paper arts.

RELATED: The ultimate guide on laser cutting paper

The ultimate guide on laser cutting cardboard

6. Fabric: Laser cutting can create clean cuts and precise shapes on various types of fabric, including cotton, silk, polyester, and leather. It can be used for fashion, upholstery, and decorative items.

RELATED: The ultimate guide on laser cutting fabric

7. Metals: Metal is a hard materials that requires a specific laser cutter to cut it. A fiber laser is the best option for metal laser cutting as it produces higher power laser beam than other lasers. Metals such as stainless steel, aluminum, brass, and copper can be easily laser cut with them.

8. Rubber: Laser cutting is ideal for cutting rubber materials, including silicone rubber, neoprene rubber, and natural rubber. It is used in the automotive, industrial, and medical industries.

RELATED: The ultimate guide on laser cutting rubber

9. Foam: Laser cutting is perfect for cutting foam materials, including foam rubber, EVA foam, and polyurethane foam. It can create precise shapes and designs for packaging, cosplay costumes, and props.

RELATED: The ultimate guide on laser cutting foam

Materials That Can Not Be Cut with Laser Cutting

Here are some examples of such materials to be cautious of when considering laser cutting:

1. PVC and Vinyl: Cutting PVC with a laser cutter machine produces hydrochloric acid gas, which can damage the laser and pose a health risk to those nearby. PVC and vinyl should be avoided to laser cut, cut them using a vinyl cutter instead.

2. Polycarbonate: While polycarbonate is impact-resistant, it tends to melt and produce rough edges when cut with a laser. Other cutting methods, such as sawing or routing, are better suited for this material. 

Laser Cutting Applications

As a highly accurate and efficient technology, laser cutting has been applied to various industries such as manufacturing, automotive, aerospace, construction, medical, and textiles. 

With the advent of compact and affordable laser cutting machines, this technology has become increasingly popular among DIYers, hobbyists, artists, and designers as well.It is being used for crafting, DIY projects, and even for running small businesses.

 Here are some examples of the diverse applications of compact and desktop laser cutting machines in various industries:

Arts and Crafts 

Laser cutting has become a favorite tool of many artists and crafters due to its precision and versatility. Laser cutting machines can be used to create intricate designs on a variety of materials. From jewelry making to paper crafting, laser cutting can produce stunning and unique designs.

Home and Decor

Laser cutting machines are also being used by homeowners and interior designers to create unique home decor and furnishings. From laser cut wooden wall art to personalized wooden signs, laser cutting machines allow for the creation of custom decor and furnishings that reflect the homeowner's personal style.

Fashion and Textiles

Laser cutting machines are becoming increasingly popular in the fashion and textiles industry. They can be used to cut and engrave a variety of fabrics and textiles, creating intricate designs and patterns. Laser cutting can be used to produce custom clothing, accessories, and even footwear.

Signage and Branding

Laser cutting is an effective way to create custom signage and branding materials for businesses. This technology allows for the creation of intricate designs and letters that would be impossible to achieve with traditional methods. Laser cutting is used to produce signage, lettering, logos, and branding materials such as business cards, brochures, and packaging.

Jewelry Making

Jewelry designers can use laser cutting machines to create intricate and precise designs on a variety of materials such as metal, acrylic, and wood. The technology also enables the production of custom jewelry pieces with personalized designs for wedding rings, necklaces, bracelets, and more.

Wedding Decor

Laser cut designs on table settings, wedding invitations, and decorative pieces can give a unique and personalized touch to the wedding decor. The technology can also be used to create custom laser cut wedding favors for guests and personalized wedding gifts for the newlywed.

Gift Making

For gift making, laser cutting machines allow for the creation of custom designs on a variety of materials such as wood, leather, and acrylic. From personalized keychains to custom wooden plaques, laser cutting can help create unique and memorable gifts for any occasion.

Laser Cutting FAQs

Q1: What is a laser kerf, and should I be worried about it?

A laser kerf is the width of the cut made by the laser beam. It is produced as a result of the laser beam melting and vaporizing the material as it cuts through it. When the laser beam melts and vaporizes the material, it creates a narrow channel or groove that is slightly wider than the diameter of the laser beam itself.

It's important to take the laser kerf into account when designing your project because it can affect the fit of your pieces. If your design requires precise fits or interlocking pieces, the laser kerf may be a concern.

However, most laser cutters have a very small kerf, typically less than 0.1mm, so it's not usually a major concern. If you're unsure about the kerf of your laser cutter, you can test it by cutting a small sample piece and measuring the width of the cut.

Q2: How are laser cutting settings set?

Laser cutting settings, such as power and speed, are set based on the material being cut and the desired outcome. Different materials require different settings to achieve the best results.

For example, cutting through thicker materials will require more power and a slower speed, while engraving or etching may require a lower power setting and a higher speed.

The settings are usually adjusted using the control software that comes with the laser cutter. The software will allow you to adjust the power of the laser, the speed at which it moves, and the frequency of the laser pulses.

The best way to determine the ideal laser cutting settings for your project is to test different settings on a small piece of the material you plan to use. Start with a low power and speed setting and gradually increase them until you achieve the desired outcome. Keep in mind that different materials will require different settings, so you may need to adjust the settings for each new material you work with.

Q3: How thick can a laser cutter machine cut?

The thickness of the material that a laser cutter can cut will depend on several factors, including the power and speed of the laser, the type of material and the focal length of the laser beam.

Keep in mind that the thicker the material, the slower the cutting speed will be, and the more power the laser will require.  It's important to check the specifications of your laser cutter to determine its cutting capabilities.

Q4: How long does laser cutting take?

The duration of a laser cutting project varies based on several factors including design complexity, material type and thickness, laser power, cutting speed, and number of passes. For example,  simple design on medium-thickness acrylic with a moderately powered laser might take a few minutes, while a complex design on thick steel could take an hour or more.

Q5: What laser can cut metal?

To cut metal, you'll typically need a fiber laser cutter. Fiber lasers are powerful enough to cut through metals such as stainless steel, aluminum, brass, and copper. 

Q6: Can you laser cut vinyl?

Laser cutting vinyl is generally not recommended due to safety concerns. When vinyl is cut using a laser, it produces fumes that are harmful to human health.

Q7: What is the difference between cnc cutting and laser cutting?

CNC (Computer Numerical Control) cutting and laser cutting are both subtractive manufacturing processes used to cut and shape materials. CNC cutting uses a computer-controlled machine moving a tool (like a drill or router) to cut materials. Laser cutting is also a type of CNC cutting, however it uses a high-powered laser to cut materials.

Q8: Is laser cutting profitable?

Yes, laser cutting can be profitable. Laser cutting allows you to create unique, custom products that can't be easily replicated by other methods. This can give you a competitive edge and help you charge a premium for your services. 

Q9: What are some tips for good laser cutting results?

1. Choose the right material for your project. Different materials will require different laser cutting settings and may have different limitations in terms of thickness and cutting speed.

2. Use high-quality design software to create your designs. Vector files are preferred for laser cutting because they allow for precise shapes and paths that the laser cutter can follow accurately.

3. Test your laser cutting settings on a small sample piece before cutting your final design. This will help you achieve the best possible results.

4. Keep your laser cutter clean and well-maintained. Regular cleaning and maintenance can help prolong the life of your equipment and ensure consistent results.

5. Experiment with different techniques, such as engraving and etching, to create unique and custom designs that can set you apart from the competition.

6. Practice safety precautions when working with laser cutters, such as wearing appropriate eye protection and ensuring that the laser cutter is properly ventilated.