Did you know that your LASER engraving system is also a very powerful cutting tool?  Low powered CO2 lasers can cut through a range of thin materials including wood, cork, plastics, paper materials, acrylic, vinyl masks and overlays, and fabrics.  For many laser owners, this translates into new profit centers including: signage,  nametags, acrylic and vinyl letters, balsa wood cutouts, matboard, archectural models,  Christmas ornaments, craft items, and miniatures, just to name a few.

Most laser engraving system manufacturers recommend that materials up to ¼” thick can be cut with a 25 watt laser. Higher wattages will be capable of cutting though thicker materials. There may also be materials, due to their hardness and density that do not cut well including metals and glass. Multiple passes may be required or, in some cases, a more powerful laser will be needed. If you are buying your system specifically for cutting, you will want to make sure that the system you buy has enough Power to cut through the desired materials profitably.  

Turn the laser on

To use your system as a cutting tool is relatively simple.  You will want to be in a vector mode as opposed to a Raster engraving mode. The vector mode allows the laser to follow an outline and move in a point to point motion, while the raster mode allows for a continuous back and for the motion by the laser. Most systems are built to switch from raster engraving to Vector Cutting as determined by the line thickness.  For best results, consult the original equipment manufacturer’s manual for your specific system. 

Similar to engraving, the artwork is laid out in your graphics program. Make sure that the graphics package you are using allows for outline capabilities or cutting will not be possible.  Tiff images may need to be converted to a HPGL format prior to cutting.  Use lines as thin as possible when vector cutting.  Adjust PPI (pulses per inch) for cutting purposes at 150 or above.  Less than 150 will result in pulses being spread so far apart that they will not touch one another.  This can be advantageous for some cutting applications such as perforating paper products or making multiples of rubberstamps and keeping them together while still on the machine. 

You will set the power and Speed just like you do for engraving jobs, but typically speeds will be lower to allow the Laser Beam to completely cut through the specific material.  Power settings will vary depending on the material and the desired result.  Some materials will also cut cleaner when one or both sides are masked and/or dampened.  Manufacturers do have recommendations for a variety of sample materials in their manuals.  For best results, you will want to experiment to find the optimal settings.  Be sure to also save these settings for future jobs that require same or similar materials. The manufacturers of materials may also have recommendations, as many of today’s laserable materials are made with these machines in mind.

Many products can be made from start to finish using both the raster engraving and vector cutting modes.  For best results use your machine s color mapping function to designate the required different settings.

When using both modes, the laser will perform all raster engraving functions first.  When the engraving is through, the systems will then cut out any shapes as designated for vector cutting.  This combined process works well when making products such as nametags, signage, key fobs, etc.

Cutting Aids

There are also options available for your machine that you will assist you in achieving clean undistorted results.  For successful laser cutting, you will want to keep the material up and off of the machines’ table top. This will give you an air flow between the table top and the material, helping to minimize potential damage caused by smoke, debris, and overheating. The result is a cleaner and more attractive edge. These tables also prevent the laser Beam from reflecting directly off of the table top and the machine and onto the underside of the material.  Beam reflection can cause damage to the material.  These tables are built to allow the energy of the laser beam to diffuse over a wide area, thus reducing damage to material and/or machine surfaces.  Systems manufacturers or after market providers can help you with the purchase of cutting tables made for this purpose.  You can also make your own using some of the following materials: light egg crate diffuser panels, fire retardant treated paper honeycomb, aluminum or stainless steel honeycomb, or fine metal screening.

Another available option is a Vacuum Work Support Table.  These are usually made of aluminum and drilled with numerous small holes.  The vacuum suction will hold the material flat and is specifically advantageous for the cutting of flexible materials like paper products, fabrics, flexible brass and engravers plastic.  By keeping the material flat while laser cutting will ensure you better quality and consistency.

Another option is downside exhaust work support tables.  This kind of support table also hold the part up off of the reflective table top as well as hold parts flat.  Additionally it will allow smoke, vaporized materials and fumes to be pulled down and away from the point of laser contact.  This will result in less smoke damage and provide greater consistent laser power where it is needed and less of the laser power being absorbed by heat and smoke and debris.  The overall effect is a more consistent quality cut and less clean up of finished parts.  If you are going to do a lot of cutting, a vector vacuum or downside exhaust table is highly recommended. They are built to mount directly on top of the engraving tabletop and usually will come with their own datum stops or rulers.  The original equipment manufacturer and/or after market providers can recommend one that will work best.

Another option available on many systems is Air Assist that works by blowing a fine stream of air across the engraving surface.  This will aid you in keeping debris, fumes, and smoke away from the point where the laser focuses onto the material. 

Exhaust it

If you are going to be cutting large amounts of acrylic and/or plastics, odor will also become an issue. The best advice is to operate the system in a well-ventilated room, and use an Exhaust System that is recommended for this type of application.

If you are going to be cutting polymer mat (rubber stamps), consider a charcoal filtration, bubbler, or sprayer type of exhaust system.  Check with air filtration companies for their recommendations.

Summary

The great versatility of lasers is again evident in the superb cutting capabilities provided for with your laser engraving system.