Laser Cutting: Things You Need to Know

Laser cutting has emerged as a game-changing technology in modern making and manufacturing. This process utilizes a highly focused laser beam to precisely cut materials with unmatched precision. Whether you're a hobbyist making DIY projects, an artist or a designer creating prototypes, or a business seeking efficient production solutions, understanding laser cutting is increasingly valuable.

In this article, we'll explain how it works and the crucial settings controlling the process. Then, we'll explore the different types of laser cutters available and the materials they can handle. You’ll also discover the diverse applications of this technology and gain practical insights into designing for laser cutting. Plus, we’ll even touch on related technologies to give you the full picture of digital fabrication.

How Does Laser Cutting Work?

Laser cutting process is directed by computer numerical control (CNC) software. Once the design and settings are provided, the software moves the laser head/module accordingly.

The laser beam vaporizes the material along the path, penetrating it and cutting it into the desired shape.

The process can be completed in one pass if the laser is powerful enough; otherwise, several passes are needed.

Besides cutting, laser cutters can also engrave or etch into materials to create designs on them.

Laser Cutting Settings

Laser cutting needs right settings to deliver the optimal results. The primary settings you'll be working with are Power, Speed, Pass and specifically for engraving, Lines per CM or Dots per Inch.

Power

Laser power indicates the strength or intensity of the laser beam emitted from the laser source. It’s usually measured as a percentage of the laser's maximum power output (e.g., 50% power on a 100W laser means 50 Watts are being used).

Power primarily dictates cutting depth and engraving darkness. The higher the power, the deeper cuts or darker engraving you'll get. High power is essential for cutting thicker materials.

Speed

Laser speed refers to how quickly the laser head moves across the material while cutting. It's usually expressed in millimeters per second (mm/s). 

Slower speed means the laser beam dwells longer in one spot, allowing it to cut deeper or engrave more intensely.

Pass

Passes determine how many times the laser beam will trace the exact same cutting or engraving path.

More passes can increase cutting depth on thicker materials or achieve deeper, more pronounced engravings.

Some laser cutter software packages material settings library to help uses to start their projects quickly, such as xTool Creative Space.

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 cutters 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 most common non-metals and engraving certain metals. 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.

Quick Comparison

Related Reading: Fiber vs CO2 vs Diode Laser

Materials You Can Laser Cut

One of the most exciting aspects of laser cutting is the wide range of materials you can work with. However, it's also necessary to understand material compatibility for both achieving good results and ensuring your safety and the longevity of your laser cutter. 

Let's explore the spectrum of laser cutting materials:

Wood

• Types: Plywood, MDF (Medium Density Fiberboard), balsa wood, basswood, birch, cherry, walnut, and many other hardwoods and softwoods.
• Machine Types: CO2 and Diode lasers.

Related Reading: Laser cutting wood guide

Laser cutting plywood guide

Laser cutting MDF guide

Acrylic

• Types: Cast acrylic and extruded acrylic. Cast acrylic is generally preferred for laser cutting as it produces cleaner cuts and engraves more evenly. Available in a vast array of colors, thicknesses, and opacities (clear, opaque, translucent).
• Machine Types: CO2 lasers for all acrylic; Diode lasers for opaque acrylic only.

Related Reading: The ultimate guide on laser cutting acrylic

Paper & Cardstock

• Types: Printer paper, cardstock, construction paper, specialty papers, parchment paper, and even cardboard.
• Machine Types: CO2 and Diode lasers.

Related Reading: The ultimate guide on laser cutting paper

The ultimate guide on laser cutting cardboard

Fabrics & Textiles

• Types: Felt, fleece, cotton, denim, silk, polyester, some leathers, and various other fabrics. 
• Machine Types: CO2 and Diode lasers.

Related Reading: The ultimate guide on laser cutting fabric

Leather

• Types: Genuine and synthetic leather.
• Machine Types: CO2 and Diode lasers.

Related Reading: The ultimate guide on laser cutting leather

Plastics (Beyond Acrylic)

• Types: Polymethyl methacrylate (PPMA)(Acrylic), Delrin, Mylar, Polyimide, Polyester, Polyurethane, and Polyethylene terephthalate (PET).
• Machine Types: CO2 lasers, Diode lasers (for opaque variants only) and Fiber lasers (engraving only)

Related Reading: The ultimate guide on laser cutting plastic

Rubber

• Types: Natural and silicone rubber.
• Machine Types: CO2 and Diode lasers.

Related Reading: The ultimate guide on laser cutting rubber

Foam

• Types: Ethylene-Vinyl Acetate (EVA), polyethylene, polyurethane, styrofoam, and polystyrene foam.
• Machine Types: CO2 and Diode lasers.

RELATED: The ultimate guide on laser cutting foam

Metal

• Types: Stainless steel, aluminum, brass, copper, and more.
• Machine Types: Fiber lasers.

Here are some materials to never laser cut:

1. PVC and Vinyl: Cutting PVC with a laser 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:

Prototyping & Product Development

Laser cutting is revolutionary for prototyping and product development. Engineers and designers can quickly materialize their concepts into tangible prototypes, enabling immediate evaluation of form, fit, and function. 

Personalized Gifts & Crafts

Laser cutting technology provides a highly effective method for creating customized gifts and bespoke home craft items.

For personalized gifts, laser cutters facilitate the creation of items such as custom engraved cutting boards, tumblers and glasswares, and accessories like earrings and wallets.

Within home crafts, laser cutting enable creations of both decorative and functional items. Examples include custom-designed wall art, clock faces, welcome signs, and coasters, suitable for various materials. Laser cutters can also be used to fabricate functional home organization items such as spice racks and drawer organizers.

Art & Design & Fashion

Laser cutting provides the art, design, and fashion industries with advanced capabilities for intricate fabrication and design execution. 

Artists leverage laser cutting for the creation of layered artwork, woodcut-style pieces, acrylic sculptures, and laser-engraved artistic panels.

Beyond direct creation, laser cutters are valuable tools for generating stencils and printing blocks for various artistic processes. These support precise and repeatable results in painting, printmaking, and mixed media applications.

In fashion and jewelry design, laser cutting technology allows for the efficient and precise production of fabric appliques, intricate lace patterns, detailed garment elements, and also for the creation of precisely-cut ewelry pieces.

Signage and Branding

For retail environments, laser-cut signs, logos, and point-of-sale displays provide durable and visually prominent elements for attracting customer attention and reinforcing brand identity.

In architectural and corporate contexts, laser cutting facilitates the production of signage systems. This includes wayfinding signage, directional indicators, room identification, and directories.

For events and promotional activities, laser-cut signage offers customizable banners, table numbers, and promotional displays.

Architecture & Model Making

Architects and model makers utilize laser cutters to construct models of buildings, structures, and urban landscapes.

Interior designers also employ laser cutting to fabricate miniature furniture components, room layouts, and interior elements.

Education

Educational institutions use laser cutters for interactive STEM projects, engaging students in robotics and engineering design.

Laser cutters also aid in creating educational models and learning aids, such as laser-cut puzzles. 

Design for Laser Cutting

This section outlines the general steps and essential software tools for designing for laser cutting.

General Design Workflow for Laser Cutting

Step 1: Choosing Vector Graphics Software

Laser cutters operate using vector paths. Therefore, vector graphics software is essential. This software allows you to create clean and scalable lines for laser cutting.

Step 2: Creating Your Design in Vector Software

Within your chosen vector software, use drawing tools to create shapes, lines, and curves that define the outlines for cutting.

Step 3: Setting up Layers and Colors

Laser cutter software typically uses color layers to distinguish between different operations:

• Cutting Paths: Usually designated by a specific color (e.g., red) and line thickness.
• Raster Engraving Areas: Assigned a different color (e.g., black or filled shapes) and may be placed on a separate layer.
• Score/Vector Engrave Paths: Yet another color (e.g., blue) to represent vector engravings.

Refer to your laser cutter’s software documentation for the specific color conventions it uses for defining operations. Proper layer setup is critical for instructing the laser cutter on how to process different parts of your design.

Step 4: Exporting in the Vector-based File Format

Once your design is complete and layers are properly configured, you need to export it in a vector file format that is compatible with your laser cutter's software. Common and widely supported vector formats for laser cutting include SVG, AI, DXF, and PDF.

Step 5: Importing into Laser Cutter Software and Adjusting Settings

Open your exported vector file in your laser cutter’s control software. Here you will:

• Verify Design Scale and Placement: Ensure your design is sized correctly and positioned as desired on the virtual work area representing your laser cutter bed.
• Define Laser Settings per Layer/Color: Assign specific laser settings we've discussed earlier to each color layer or operation defined in your design file. 
• Initiate Laser Cutting/Engraving: Once all settings are verified, send the job to the laser cutter to begin the process.

Related Reading: Websites to download free laser-cut files

Choosing Your Design Software

The best software for you depends on your budget, design needs, and desired level of complexity.

• Beginner/Hobbyist/Budget-Conscious: Inkscape is an excellent starting point due to its free and open-source nature and powerful capabilities.
• Professional/Industry Standard: Adobe Illustrator remains the industry benchmark with its extensive features and broad compatibility.
• Professional/Mid-Range Budget/Perpetual License Preference: CorelDRAW or Affinity Designer offer robust features and professional capabilities with different licensing models to consider.

Vector Cutting vs Rastering

The versatility of laser cutters comes from their ability to operate in two primary modes: Vector Cutting and Laser Rastering (Engraving). They utilize the laser beam in fundamentally different ways to achieve distinct results.

What is Vector Cutting?

Vector cutting is exactly what it sounds like – cutting along vector paths. In this mode, the laser beam follows the lines and curves you define in your design file to completely cut through the material, separating it along the designated lines.

What is Laser Rastering?

Laser rastering, often referred to as laser engraving, works much like a printer. In this mode, the laser beam scans back and forth across the material surface, line by line, similar to how an inkjet or laser printer applies ink to paper. Instead of cutting through, rastering marks or etches the surface of the material.

Laser Cutting Kerf

Kerf in laser cutting refers to the width of material removed by the laser beam as it cuts. Think of it as the laser having a cutting width, not just a zero-width line. While seemingly small, this kerf is a crucial factor for precise laser cutting, especially when parts need to fit together.

Learn More: How to compensate for laser cutting kerf?

Joinery Techniques: Joints, Stacking, and Living Hinges

While laser cutters excel at 2D shapes, smart design techniques enable you to create 3D structures. This section explores three key joinery techniques that leverage laser cutting: Joints, Stacking, and Living Hinges.

Joints

Laser-cut joints allow you to interlock and connect pieces, forming more complex 3D structures without the need for fasteners like screws or nails in many cases. 

Here are some common laser-cut joints:

Finger Joints (Comb Joints)

Interlocking "fingers" increase the glue surface area significantly, resulting in very strong joints.

Tab and Slot Joints

One of the simplest and most common. Tabs on one piece insert into corresponding slots on another, providing good alignment and mechanical strength.

Mortise and Tenon Joints 

Source: yrac - Designfind.com

A classic woodworking joint adapted for laser cutting. One piece features a mortise – a precisely cut cavity or hole, and the mating piece has a tenon – designed to fit snugly into the mortise.

Stacking (Layering)

Source: LlamaBigMac - Designfind.com

Stacking, also known as layering, is a technique where you laser cut multiple 2D slices or contours of a 3D object and then stack and adhere them together to build up a 3D form.

Living Hinges

Source: MM - Designfind.com

The laser cuts away specific patterns of material, creating thin, flexible sections (the "hinges") separated by thicker, more rigid segments. These thin sections allow the material to bend and flex along the hinge lines, creating a functional hinge from a normally inflexible material.

Related Technologies

Here, we briefly explore some key technologies related to and often complementary to laser cutting:

CNC Milling/Routing

CNC (Computer Numerical Control) milling and routing are also subtractive manufacturing processes, like laser cutting, but they use rotary cutting tools instead of lasers to remove material. A CNC mill or router uses a spinning bit to carve away material from a solid block or sheet, guided by computer-controlled paths.

Learn More: CNC vs Laser Cutter

3D Printing

3D printing, also known as additive manufacturing, is fundamentally different from laser cutting and CNC milling. Instead of removing material, 3D printing builds up a 3D object layer by layer. Various 3D printing technologies exist, using materials like plastics, resins, metals, and ceramics.

Learn More: 3D Printer vs Laser Cutter