As the digital world opens up doors for people to start their own businesses, laser cutting machines are one way people can turn their passion projects into viable businesses. Although CO2 laser cutting machines have been around since the s, theyve largely been the reserve of huge industrial companies. Nowadays, pretty much anyone can buy this equipment, learn how to use it and produce marketable merchandise, art or crafts products.
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At Thunder Laser USA, we offer laser cutting machines of the highest quality at affordable prices. If youre looking for a route to start working for yourself, laser engraving or cutting could be just the answer. You dont need previous experience, and you dont even need to be able to draw by hand. Read on to find out more about carbon dioxide laser cutters and how to use them.
Laser cutting is simply the process of using a laser beam to cut through the surface of a material. You might do this for a number of reasons, including finishing, trimming, engraving or cutting any complex shape that a drill or manual tool might struggle with. Its possible to cut a broad range of materials using a laser, which well explore in more detail later on in this article.
A precise and focused laser beam runs through the surface of the material youre engraving or cutting, resulting in a smooth, clean finish. The machine starts off by piercing a hole at the edge of the design, and then the beam runs up and along the pathway programmed into the laser cutter.
The laser works because it melts away the material it runs across, so it is actually a laser melting machine as opposed to a laser cutting machine! As such, it can cut anything from delicate materials like cloth to tough gemstones like diamonds. The laser cutting process is accurate and offers full control over the finish, letting you create cuts and engravings that are as tiny or huge as necessary.
Western Electric created the first production laser in , using the precise method to punch holes into diamond dies. In , a German scientist developed a nozzle laser cutter that used a CO2 laser beam and oxygen-assist gas to cut a 1mm steel sheet. With the race to develop this technology well and truly on, Boeing got involved a few years later and conceptualized that these machines could be used to cut materials like ceramic and titanium.
A modern CO2 laser cutting system was first introduced in . By the s, industrial entrepreneurs saw the opportunity for making serious money with engraving. Nowadays, any plucky individual or group of ambitious people can buy a laser cutting machine and start their own artisan engraving company.
Modern CO2 machines produce a laser beam in a glass tube that is sealed and filled with carbon dioxide. A high current is sent through the tube, which creates a reaction with the CO2, increasing the energy of the gas particles so that they produce light. When you create light with this level of brightness, the byproduct is intense heat. This heat is strong enough to melt materials with enormously high melting points.
Theres a partially reflective mirror at one end of the tube and a fully reflective mirror on the other side. Light is reflected backward and forwards across the length of the tube. These mirrors help to intensify the light so that it can vaporize most materials. Once the light is bright enough, it passes through the partially reflective mirror. The full mirror guides the laser beam out of the tube and toward a subset of mirrors that the machine uses to create the desired design.
The final mirror is on the inside of the laser head, and it directs the laser through the focus lens onto the material youre working on. The role of the focus lens is to refine the lasers pathway so its focused on an exact spot. This extra focusing process is what makes a CO2 laser cutter able to produce such precise and clean finishes on a broad range of materials.
The machine also houses a computer numerical control system that allows it to position the laser head in all directions over the work bed. This works alongside the mirrors and focus lens so the beam can create different shapes without losing accuracy or power. The laser can switch on and off at an incredible speed, allowing the operators to engrave beautiful, intricate designs.
There are three main functions you can perform using a carbon dioxide laser cutting machine: cutting, engraving and marking.
When you use the laser to cut, the beam goes all the way through the material of your chosen substrate. Laser cuts tend to be extremely clean and precise, although it does depend on the material youre using. For instance, wooden edges tend to have a darker finish than the original color of the wood. One of the best materials for laser cutting is acrylic, which has a lovely glossy and smooth finish, with no discoloration.
Marking is the other end of the spectrum from cutting. Instead of melting or removing the material, it simply alters the surface. The only time youd use a CO2 laser for marking would be if your chosen substrate was metal. To make this work, youd use a marking solution to prime the material. Once dry, it reacts with the laser beam to leave a permanent mark.
Engraving is perhaps the most popular current usage for laser cutting professionals because it lets them customize pretty much anything. When you engrave using a CO2 laser, you remove the top layer without cutting all the way through the object. From keychains to glassware and apparel, theres a lot you can do with one of these.
Some materials must not go anywhere near a CO2 laser cutting machine. Some of these include halogens, phenolic resins, epoxy, beryllium oxide, Teflon, PVB, PVC, carbon and any artificial or real leather containing chromium. Heres a table of materials that are generally effective and safe for use with a laser engraving machine.
Material Engrave Cut ExplanationAluminum
No
No
Marking is possible
Stainless steel
No
No
Marking is possible
Glass
Yes
No
Ceramic
Yes
No
Porcelain
Yes
No
Stone tiles
Yes
No
Slate
Yes
No
Marble
Yes
No
Granite
Yes
No
Polypropylene (PP)
Yes
Yes
Prone to melting
High-density polyethylene (HDPE)
Yes
Yes
Very volatile for both
Delrin (POM, acetal)
Yes
Yes
Acrylic (Plexiglas)
Yes
Yes
Cotton
Yes
Yes
Felt
Yes
Yes
Leather
Yes
Yes
Works best with vegetable-tanned leather
Paper
Yes
Yes
Cardboard
Yes
Yes
Cork
Yes
Yes
Plywood
Yes
Yes
Make sure the plywood has interior not exterior glue
Wood
Yes
Yes
One of the best ways to think of a laser cutting machine is as a very similar tool to an inkjet printer. The equipment comes with specific drivers that let you convert an image from a computer into a file that the laser cutter is able to read. When working with this machine, you need to understand the difference between raster images and vector images.
Vector images store the colors and lines as mathematical formulas. Some of the vector file types include Adobe Illustrator, CorelDRAW, DWG, DXF, PDF, EPS and SVG.
Raster images are pixelated, meaning the images are made up of lots of tiny squares. Files types include GIF, PNG and JPG.
You can scale vector images up and down without compromising the quality, but raster images will start to pixelate and appear distorted at a certain point of enlargement.
For cutting all the way through the material, the laser cutting machine requires a vector path as the input file. The laser will only cut through vector graphics with minute line thicknesses. It wont cut other graphics like thicker lines or solid shapes.
Its possible to distinguish between vector and raster images with a CO2 laser cutting machine. Vector engraving is practically the same as cutting, except the laser only removes part of the material instead of vaporizing all the way through.
Raster engraving can be carried out using a vector or raster image file. With this type of work, the laser engraves the image pixel by pixel, line by line. Its similar to the way an inkjet printer applies ink to a piece of paper except the laser is removing the surface of the material instead of writing something on it.
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When your design is ready in your chosen file format, its time to get to work. You can do seriously amazing things at record speed with a laser marking machine, but as powerful as it is, its also dangerous.
Before conducting any work with one of these tools, thoroughly read the safety instructions and make sure you understand them. Its also important that you understand that the CO2 laser is infra-red, which means its not visible to the human eye. Any red dots you can see are usually tools for positioning as opposed to the laser beam itself.
First, youll need to check that your design fits into the work area so you can trim it back if necessary. Its also advisable that you bring some spare material just in case, especially if this is your first time using a laser cutter.
Although the laser cutting machine is technically the only tool you need for the job, its a good idea to have the following on-hand:
Calipers or measurement tape: Its sensible to be precise when it comes to measuring dimensions and performing quality control.
Masking tape: Tape down light materials and use it on volatile materials to prevent burn stains.
A utility knife: Cut your materials to size before placing them into the work area where the laser cutter is.
There are three crucial settings when it comes to using a laser cutting machine:
Focus: Inside the laser head, theres a focus lens that ensures the final finish is clean and smooth. The focal point should be on or slightly below the material surface. As such, you need to make sure the material is always a certain distance away from the lens this varies according to the individual machine.
Speed: The speed setting determines how fast the laser head moves for engraving and cutting of thinner materials, the speed should be set near to the maximum.
Power: Youll need to define the output power of the laser anywhere between 0 and 100%. High power is ideal for thick materials, and low power is more suited to cutting or engraving thin materials like paper.
Now youre all set to start engraving or cutting. It might take a bit of practice to find the settings that produce the best results, but this is all part of the learning curve. Once youve gotten to know your machine, itll run like a dream every time.
When youre in the testing process, make sure you only change one parameter at a time so you can find out exactly what works. When youre happy with the result, log that data somewhere safe!
The beam never actually touches the surface of the material youre working with. Rather, it causes the material to melt because of the high heat emitted by the laser. This means the materials are less prone to damage but it also means that the main appendage on the laser machine doesnt wear down over time.
Compared to other equipment that performs a similar function, a laser cutter uses a low amount of power so little that you can use it at home without the need for any special wiring. Even better, replacement parts are usually affordable.
Laser cutting is a safe way of marking, engraving or cutting because it doesnt use a blade or any other sharp implement. The laser beam is tightly sealed in glass, so as long as you carefully follow the safety instructions, theres practically no risk of injury.
The results you can produce with a CO2 laser cutting machine are extremely precise and accurate. Extreme heat and intensity from the light of the laser beam melt away the material in the design you enter into the computer. The finish is smoother and cleaner than youd be able to produce by hand. As long as you can create a computerized 3D or 2D image, you can add wording, pictures or any other design to a broad range of materials.
There are many different industries and applications where laser cutting machines are useful. From medical equipment to art, there are so many different ways you can make money using a laser cutting machine.
If youre brimming with ideas for engraving or cutting with a CO2 laser cutter, take a look at the awesome range of machines at Thunder Laser USA.
Diode vs CO2 vs Fiber Laser Engraver: Which Laser to Choose?
1. Materials the Lasers Can Cut and Engrave
The decision to select a type of laser first depends on the materials you want to engrave and cut. First of all, if a laser can cut certain materials, it can also engrave them. But if a laser can engrave certain materials, it is not necessary it can cut them. For cutting, high power is needed compared to engraving.
a. Materials Compatible with Dioder Laser Engravers
If you want a laser machine for crafting or starting a small business, a diode laser is a suitable option as it can cut and engrave a wide range of materials we commonly use. Diode laser machines can easily cut wood, plywood, acrylic(opaque), cardboard, paper, and leather. These are the common materials that almost all laser diode machines can cut according to their power.
The materials that can be engraved by a diode laser engraver are wood, plywood, acrylic, paper, leather, metals, glass, ceramics, and a few more materials.
Engraving
Cutting
Wood
Wood
Plywood
Plywood
MDF
MDF
Leather
Felt
Paper
Leather
Some opaque acrylic
Paper
Dark glass
Some dark acrylic
Stone/Ceramic/Jade/Marble/Shale/Cement/Brick
Plated metal/Coated metal
Fabric
b. Materials Compatible with CO2 Laser Engravers
CO2 laser machines are better than diode laser machines in terms of cutting materials. They can cut and engrave a broader range of materials. And due to its 10,640nm wavelength being absorbed the majority of non-metals, CO2 laser engravers can work on almost all non-metals.
A CO2 laser can cut wood, plywood, MDF, acrylic (all colors), foam, paper, cardboard, leather, plastics, fabric, and rubber. The materials that a CO2 laser can engrave are acrylic (all colors), wood, plywood, MDF, leather, plastic, glass, fabric, rubber, brick, ceramics, bone, and coated metals.
Engraving
Cutting
Acrylic (all colors)/Plastic
Acrylic (all colors)/Plastic
Wood/Plywood
Wood/Plywood
MDF
MDF
Leather
Fabric
Paper
Leather
Glass
Paper
Rubber
Foam
Stone/Ceramic/Jade/Marble/Shale/Cement/Brick
Rubber
Plated metal/Coated metal
Fabric
c. Fiber Laser Engravers
Fiber laser machines can cut and engrave most metals and some non-metals. It cuts and marks metals that other laser machines cannot do. They can engrave and cut aluminum, brass, copper, ceramics, tungsten, chrome, painted metal, fiberglass, carbon fiber, nickel, silver, gold, stainless steel, plastics, etc.
2. Laser Power
Beginners need to understand a few things while considering the power of a laser machine. There are three types of power ratings mentioned for laser machines. The three types are laser optical/output power, laser electric power, and machine power.
Machine power refers to the input power of the machines. It does not represent the power of a laser. The second one is the laser electric power, which is the input electrical energy taken by the laser module. The power is related to the laser module, but it does not represent the ability of the laser to engrave and cut an object. However, it can be used to understand the electricity consumption of the laser module.
The most important power is the laser optical/output power. It is the power that shows the ability to cut and engrave materials. The laser coming out of the module has optical power, and buyers need to see this power to understand what a laser machine can do.
The machine power rating is always the highest, and then comes the laser electrical power, and finally the laser optical power. For instance, a diode laser machine has an optical power of 10W, electric power of 40W, and machine power of 60W. Beginners get confused between laser electrical power and optical power. Some companies also scam people by telling them the electrical power instead of optical power. Thus, you always need to see the optical power of the machine for comparison.
Diode lasers have the lowest optical power compared to other types of laser engravers. They are typically 5-40W. However, they can cut and engrave all materials we have discussed. Even this low power is suitable for small businesses. If the power is low, then there will be more passes required to cut or engrave the materials.
xTool has introduced the world's most powerful diode laser module with 40W optical power. The module is very powerful, which can cut up to 18mm wood in one pass. It does the job quickly and with high precision. It increases the efficiency of a diode laser engraver.
b. Optical Power of CO2 Laser Engravers
CO2 laser engravers are more powerful than diode lasers. They can cut more objects as the laser beams provide more heat energy. The optical power of CO2 lasers ranges from 40W to 300W, making the machine are excellent for cutting and engraving more materials.
c. Optical Power of Fiber Laser Engravers
Most fiber laser engravers available on the market are industry-grade, so these laser machines typically have an optical power over 1,000 watts. Some industrial fiber lasers can reach over 10,000 watts. They can cut metals, so you can assume how powerful they are.
For small business, desktop fiber laser engravers are also available. For example, the xTool F1 Ultra boasts a 20W fiber laser module that can perform deep engraving on all metals and even cut thin metal sheets.
One of the key factors influencing laser cutting/engraving speed is optical power. The higher the power, the faster the speed. Thus, fiber lasers typically boast the highest speeds.
Another crucial factor is the laser scanning system. Traditional XY-axis machines move the entire laser module back and forth across the material. This mechanical movement limits speed. In contrast, Galvo systems utilize mirrors to direct the laser beam, allowing for much faster and more precise movements. For example, both the xTool S1 and xTool F1 are a diode laser machine. However, the F1 with its Galvo system achieves a significantly higher speed (4,000mm/s) compared to the S1's XY-axis system (600mm/s).
If you're a DIY enthusiast or just launching your small business, a desktop diode laser engraver is an attractive option due to its affordability. Typically, desktop diode lasers range from $700 to $2,500, making them a budget-friendly entry point into the world of laser cutting and engraving.
However, as your small business flourishes and your needs evolve, you might consider upgrading to a CO2 or fiber laser engraver for wider material compatibility, improved efficiency, thicker cutting and deeper engraving.
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