What truly sets 3D laser relief engraving apart from conventional flat laser marking is the shift in processing dimensionality—from 2D grayscale to a full 3D height field. The process begins by slicing the STL mesh model into multiple layers along the Z‑axis, each defining a distinct contour path. As machining proceeds, the laser head dynamically adjusts its focus for every layer and removes material sequentially, building up the desired raised and recessed features. This approach resembles “subtractive 3D printing,” yet delivers micron‑scale precision.
Critically, the choice of layering strategy, layer thickness, and Z‑axis following speed all play a decisive role in determining the final three‑dimensional appearance and surface finish.
Embossing Seals Methods
Embossing seals can be produced in several ways; traditional mechanical engraving and machining are still widely used, but they can require specialized tooling and additional preparation when the design contains complex three-dimensional details.
3D relief engraving uses the height information contained in a three-dimensional model to create visible depth on the workpiece. Instead of treating the entire design as a single flat graphic, the software divides the model into multiple layers and controls the Z-axis position during processing.
This is the basic principle behind 3D relief engraving with the AXI Ultra. The model is first prepared as an STL file and then imported into the software. After the model is scaled, rotated, centered, and positioned correctly, the deep engraving function can be used to define how the material will be removed layer by layer.
Case Study - Flying Horse Wax Seal
To show how 3D laser engraving works in a real application, this section uses a flying horse wax seal as the example. The STL model is imported into the AXI Ultra software, scaled to fit the workpiece, and then processed layer by layer using the Deep Engraving function.
What Is an STL File and How to Prepare It
A 3D relief project requires a three-dimensional STL file as the source model. An STL file is a common 3D model format used in manufacturing, prototyping, 3D printing, and other digital fabrication processes. Unlike a JPG or PNG image, an STL model contains three-dimensional geometry. It includes width and length information as well as height and depth, allowing the model to be viewed and processed from different angles.
For 3D laser engraving, the height information in the STL model is particularly important. The software uses this information to divide the model into different processing layers. Areas with different heights can therefore be engraved to different depths, creating the relief effect.
Before importing an STL file into AXI Ultra, check that the model suits the intended application. The model should have a clear three-dimensional structure and should not contain unnecessary or damaged geometry that could create unexpected engraving paths.
How to Make Your Own STL Files
You can find STL models through online 3D model platforms or online stores such as Etsy. Depending on the design, you can purchase or download a model and then prepare it for engraving.
To make your own, you could create an STL model with a 3D scanner. If you already have a physical object, a compatible 3D scanner can be used to capture its shape and generate a digital 3D model. For the 3D scanner operation, refer to the following video:
Step-by-Step Guide
1. Import the STL model
Click "Layer", then click the Switch to 3D View icon in the upper‑right corner. Next, click "Import Mold", select the desired STL model file, open it, and finally click "OK" to confirm.
2.Adjust the model view
At this stage, make sure you can clearly identify the model in the 3D workspace before continuing with the size and position adjustments.
3. Adjust the model size
Click the "Scale Mold" option in the upper toolbar, enter 30mm in the X‑axis Dimension field, click "Apply", then use the middle mouse button scroll wheel to zoom out the interface.
4. Rotate the model
In the upper toolbar, select "Rotate Mold", input −90 in the X‑axis field and −180 in the Z‑axis field, then click "Apply" to confirm.
5. Move and position the model
In the upper toolbar, select "Move Mold", then click "Center" and press "Apply". Next, click "Below the Z‑Plane" and press "Apply" once more.
6. Switch to the 2D view and open Deep Engraving
Switch to 2D view by clicking the button in the upper‑right corner, then use the middle mouse wheel to zoom in on the canvas. Next, click "Draw" and select the Deep Engraving icon.
7. Set the Deep Engraving parameters
In the left panel, click "Deep Garving" to open its settings, then enable it by clicking "Enable". Set the layer thickness to 0.001, choose "Convex" mode, enter 0.001 for the Z‑axis downward step, input 30° for the incremental angle, and finally click "Apply".
Notes:
- Layer thickness – Defines the height increment for each slicing layer used in deep engraving of the STL model.
- Intaglio mode (negative engraving) – Excavates the STL model shape into the workpiece.
- Relief mode (positive engraving) – Removes the surrounding material, leaving only the STL model standing out.
- Z‑axis step distance – Its value is interpreted differently depending on the Motion Mode chosen in the Deep Engraving Settings; thus, it may represent different Z‑axis movements.
8. Draw the engraving boundary
In the left panel, click "Layer", then select the Circle drawing tool from the upper toolbar. In the lower‑right corner, set the dimensions to 31 mm by 31 mm, and finally click the Center button to position it in the middle.
Notes:
- Outline file path – This setting is required when using Relief mode (positive engraving). You must specify a valid path to the outline file; otherwise, relief engraving will not function, since the system needs to know the complete workpiece boundary to correctly remove the surrounding material.
- Only DXF files are supported for the outline path.
- How to import the outline file – see the usage instructions below.
9. Export the DXF file
In the lower‑left area, select the circle layer, then click the logo icon located in the upper‑left toolbar, and choose "Export DXF" to proceed.
10. Save the DXF file
Save the DXF file to your desktop. Tick the checkboxes for "Export original graphics to a DXF file" and "Output selected objects only", then click the browse button (the ellipsis …), type flying horse as the file name, click "Save", and finally click "Export".
11. Import the frame file
Select the Deep Garving layer, then click the browse button (the ellipsis …) next to the Frame file path entry. Navigate to the flying horse file we saved earlier, open it, and finally click "Apply" to confirm.
12. Set the engraving parameters
Configure the engraving parameters and preview the layer‑by‑layer slicing effect.
Select the Deep Garving layer, then click on "Mara Parameter". Enable the Fill option, set Speed to 1000, Power to 100, Pulse Width to 200, Frequency to 48, choose Laser Source 1, and finally click "Apply" to confirm.
In the upper toolbar, open the View menu and enable Mold View. Next, click the Slice icon located on the right side. Then, hold down the left mouse button and slowly drag the slider (shown in Signage 9) downward – this allows you to preview the layered slicing effect and see the total number of cut layers displayed at the bottom.
13. Set the Frame/Fill parameters
Select Frame/Fill, then enable Average Distribution (note: the interface may show "Average Distribution"). Set the Pitch to 0.03, the Number of Passes to 2, the Start Angle to 45°, and the Incremental Angle to 90°, then click Apply to confirm.
14. Align the red dot positioning
On the machine's control panel, you will see two red alignment dots. Position your stamp directly over these dots, then use the up/down buttons located on the right side of the machine to adjust the height until the two red dots merge into one.
15. Preview the engraving path
In the left panel, select the Circle Layer, then enable the Full Path and Selected Only checkboxes, and finally click "Preview" to proceed.
16. Position the seal according to the preview
Position your stamp over the red laser preview area, as illustrated in the figure below.
17. Start the engraving
Select the Deep Garving layer in the panel, then click the Marking icon at the upper right. Next, open System Settings, tick the Show Object list checkbox, click OK to confirm, and finally click Exec to start the job.
18. Monitor the engraving progress
In the Object Content panel at the bottom right, you will see the engraving progress displayed as 1/2321 – meaning 1 pass out of a total of 2321 passes has been completed. Please ensure the protective cover is closed while engraving. Should any problem arise, you can use the Pause or Stop function immediately.
Once the process is complete, you will have the finished flying horse seal. This example takes approximately 6–8 hours.
The relatively long processing time is normal for this type of 3D laser engraving. Unlike a simple surface marking job, the AXI Ultra must process many individual layers to reproduce the depth information in the STL model.
Common Questions for 3D Laser Engraving
3D laser engraving requires more preparation than a standard 2D engraving job. The quality of the final relief can be affected by the STL model, layer structure, engraving parameters, and focal position. The following are some common problems that may occur during the process.
Model Questions
Why are there random lines or irregular defects after engraving?
In the right‑hand panel of the software, you can exclude the problematic layer ranges. Drag the Slice slider on the right to identify the layers that contain chaotic line segments – for instance, layers 2780 through 3398 may be affected. Once you have determined the range, enter those start and end values into the Mark Plan field on the left and click Apply. As a result, the software will automatically bypass these messy sections during the engraving process.
Should the first approach fail to resolve the issue, you will need to repair the model using dedicated 3D repair software, or alternatively, you can choose a different model to proceed with the engraving.
Parameters Questions
Why is my 3D relief engraving too shallow?
If the finished 3D relief does not have enough depth, there are several possible adjustments you can make.
Method 1: Increase the number of cutting layers or adjust the model height.
Method 2: Reduce the marking speed and fill spacing.
Method 3: Adjust the model position and shorten the focal length.
1. Click the logo icon in the upper‑left corner, then click Options.
2. Under "3D Work Area Type", change the setting to "Type 2", then click Apply.
3. Toggle the 3D view button at the top right. A red transparent box will appear in the center of the workspace. Keep your model inside this box at all times—if it's outside, the machine won't engrave or process anything.
4. Click 3D in the top toolbar, then click Move Mold. Enter 25 as the value and click Apply.
Note:
- Higher Z value → shorter focal length → stronger laser energy
- Lower Z value → longer focal length → weaker laser energy
The correct engraving focus is achieved only when you click "Below The Z-Plane," and the two red dots on the material overlap completely.
At this point, the model is now infinitely close to the top of the rectangle. We need to go back to Step 7 and repeat the operation once more.
We have successfully shortened the focal length in the software, but we also need to physically lower the machine head to the correct position.
Note: After shortening the focal length, the two red dots overlapping is NO LONGER the correct way to check focus.
Instead, you should now observe the brightness of the laser beam and the sound it makes to determine if the focus is properly set.
