Laser cutting acrylic with a diode laser opens up endless possibilities for creativity, allowing you to transform ordinary acrylic sheets into extraordinary designs. With a diode laser, achieving clean, precise cuts and detailed engravings becomes easier and more accessible, allowing for the creation of custom signs, decorations, and art pieces. In this guide, we’ll explore how you can easily achieve stunning results with your desktop diode laser, making professional-quality cuts and engravings possible at home!
I. Can You Laser Cut Acrylic?
Yes, you can laser cut acrylic, and the process is both efficient and precise. To understand how laser cutting works on acrylic, let's dive into the principles behind it.
Acrylic, also known as plexiglass, is a thermoplastic material. This means it becomes soft and malleable when heated, which is what makes it ideal for laser cutting. The laser cutting process involves using a focused, high-intensity laser beam to cut through the acrylic. The laser beam heats the material to a point where it either melts or vaporizes, depending on the settings, leaving behind a smooth, clean edge.
II. How Does Laser Cutting Work on Acrylic?
1. Laser Beam Focus: The laser cutter uses a CO2, fiber or diode laser to direct an intense beam of light onto the acrylic surface. This beam is focused to a pinpoint precision, allowing it to cut intricate designs with extreme accuracy.
2. Melting or Vaporizing: As the laser beam moves across the acrylic, it generates heat. This heat causes the acrylic to melt or vaporize at the point of contact, effectively "cutting" through the material. Unlike traditional mechanical cutting methods, the laser does not cause any physical contact with the acrylic, which reduces the risk of cracking or chipping the material.
3. Clean Edges: One of the main benefits of laser cutting acrylic is the smooth, polished edges it leaves behind. Unlike saw cuts, which can result in rough or jagged edges, the heat from the laser seals the cut, preventing the acrylic from cracking and giving it a glossy finish.
4. Precision: Laser cutting allows for precise, detailed designs to be cut with fine lines and sharp corners. This level of accuracy makes it perfect for creating everything from simple geometric shapes to highly intricate patterns or lettering.
5. Minimal Heat Affected Zone: Because of the focused nature of the laser, the heat-affected zone (HAZ) is small, minimizing the risk of warping or discoloring the acrylic. This makes it suitable for a wide range of projects, from decorative items to functional parts.
III. Key Factors That Influence Laser Cutting Acrylic
While laser cutting acrylic is a straightforward process, several factors affect the quality and efficiency of the cut:
• Laser Power: Higher power lasers are needed for thicker acrylic sheets, while lower power lasers are suitable for thinner materials.
• Speed: The cutting speed must be adjusted based on the thickness of the acrylic. Slower speeds ensure better penetration and cleaner cuts in thicker acrylic.
• Focus: Proper focus of the laser beam is crucial for achieving the sharpest cuts and preventing overheating.
• Material Thickness: The thicker the acrylic, the more passes the laser may need to make to cut through it completely. This can also require more power to maintain a clean cut.
For optimal acrylic cutting, the EM-Smart Dual laser cutter is the ideal choice. With its dual-laser system, it easily handles both thin and thick acrylic, ensuring clean, precise cuts.
EM-Smart Dual Desktop Laser Engraver with 20W Fiber & Diode
Dual laser engraving machine for 300+ materials' deep engraving and cutting with higher precise engraving results.
Learn More >IV. Step by Step guide to laser cut Acrylic
Let’s walk through the simple steps to laser cut acrylic using the EM-Smart Dual Laser Engraver – perfect for getting those clean, professional cuts right at home!
Step 1: Preparation for Cutting Acrylic Sheet
Begin by selecting the appropriate acrylic sheet based on your project requirements. Clean the acrylic to remove any dust or debris. Set up your diode laser engraver and ensure it is in proper working order. Place the acrylic sheet on the cutting bed of the laser cutter.
Step 2: Design the Cutting File
Using LightBurn software, create or import your design. If designing from scratch, use the basic shapes tools within LightBurn to build your design, or import pre-made files in formats such as DXF, SVG, or PDF. Adjust the design as needed to fit the acrylic sheet.
Tips: Click LightBurn guide to learn the details
Step 3: Adjust the Laser Focus
Place the acrylic sheet on the cutting bed, then use the laser engraver's motorized focus system to adjust the laser’s height. This ensures the laser is precisely focused on the acrylic surface for clean and accurate cuts.
Step 4: Set the Cutting Parameters
In LightBurn, set the correct parameters for cutting acrylic. For a diode laser, a typical setup might be 80% power, 50 mm/s speed, and 20 kHz frequency. Make sure to adjust these settings based on the thickness of the acrylic you are using.
| Laser Type | Material | Power | Speed | Frequency | Line Interval |
| Diode | Acrylic | 30% | 1,000 mm/s | 20 kHz | 0.03 |
| Fiber | Acrylic | 20% | 1,000 mm/s | 20 kHz | 0.05 |
Step 5: Switch Between Laser Sources
If your engraver has multiple laser sources, such as a diode and fiber laser, ensure that the diode laser is selected for acrylic cutting. In LightBurn, select the "Use Laser 2" option to activate the diode laser.
Step 6: Preview the Cutting Path
Before starting the actual cut, use the path preview feature in LightBurn. This allows you to see how the laser will follow the design, ensuring that everything is aligned correctly and avoiding any potential cutting errors.
Step 7: Perform a Material Test
Before cutting your final design, run a test on a scrap piece of acrylic. This helps you confirm that the power and speed settings are ideal for the material and prevents issues like charring or incomplete cuts.
Step 8: Start the Cutting Process
Once everything is set up, start the cutting process. Begin with high power and speed for an efficient initial cut, then reduce the speed for finishing to avoid overheating the acrylic. Use the red light frame preview to ensure that the acrylic sheet is properly aligned with the design.
Step 9: Post-Cutting Cleanup
After the laser has finished cutting, remove the acrylic piece and check the edges. If necessary, use a soft cloth to clean any residue or a fine-grit sandpaper to smooth out any rough edges. If the acrylic sheet had a protective film, peel it off carefully after cutting.
V. FAQ
1. How do I find the right settings for engraving acrylic?
To achieve the best results, always start by testing your speed and power settings. Acrylic is sensitive to heat, so using incorrect settings can lead to warping or burning. A good starting point for cast acrylic is a speed of 1,000 mm/s and power at 20-30%. However, always test with a scrap piece of acrylic to fine-tune settings based on material thickness and type.
2. What type of acrylic should I use for engraving?
Cast acrylic is ideal for engraving, as it gives a frosty white finish and creates high-contrast designs. On the other hand, extruded acrylic can be uneven and may produce cloudy results. Thicker acrylic sheets may need lower speeds or higher power settings, and darker acrylics absorb more heat, potentially leading to burning.
3. Can I use both the fiber and diode lasers for acrylic engraving?
Yes, if you're using the EM-Smart Dual laser engraver, you can utilize both the fiber and diode lasers. Use the fiber laser for engraving solid, high-contrast base colors, then switch to the diode laser to add textures or depth for a more layered effect. This approach enhances both the clarity and complexity of your design.
4. How do I manage multiple layers with different parameters?
In LightBurn, use unique names and colors for each sub-layer to help you manage different cutting or engraving settings more efficiently. This makes it easier to differentiate layers and adjust parameters accordingly.
Short video of laser cutting acrylic
About EM Smart
At EM Smart, we specialize in providing high-quality laser machines for all your marking, engraving, and cutting needs. Whether you're looking for precision in small-scale projects or efficiency in large-volume production, our advanced machines are designed for versatility and top-notch performance. We are committed to helping you bring your creative and industrial projects to life with the best laser technology available!
