An in-depth guide to laser cutting & Engraving

Laser cutting refers to cutting any material using the laser beam. Laser engraving represents making different patterns into different types of materials. In an easy way, the laser beam burns melts, or vaporizes a certain portion of the material.

Laser machines can cut and engrave different patterns in wood, metal, glass, paper, gold, vinyl, and other 100-plus materials.

In 1961, Kumar Patel invested in the laser cutter while he was doing research in Bell Labs about laser cutting. He was the inventor of the Co2 laser cutter (a type of laser cutter that can easily engrave on acrylic, plywood, and cardboard.

How does a laser cutter work?

A laser beam, generated by the laser machine makes contact with the material to cut or place patterns. The direction of the laser beam is controlled by laser control software.

Normally, a laser beam has a diameter of 01. to 0.3 mm which makes contact with the material to place patterns. The power of the beam varies depending on the cutters and as well as the materials.

The power of the laser beam varies from 1 to 3 KW which is enough to engrave materials such as wood, vinyl, and cardboards.

However, higher power (let’s say 6 Kw) would be essential for engraving heavy metals such as Steel, Aluminium, and such. (read glossaries for more)

Here are the components that take part in the laser cutting function:

Laser Resonator

The laser beam comes from the resonator which is an airtight glass tube filled with different gases like CO2, Hydrogen, Nitrogen, etc. A mixture of these gases activates electric discharge and makes the laser beam powerful.

Cutting Head

Before the final delivery, the light bounces on several mirrors and becomes more powerful. In the final stage, the light comes into the cutting head and passes by a curved lens.

The light also gets magnified and focused on a single point so that it can cut the material with the given depth. The focused light then goes to a nozzle which is always filled with nitrogen and oxygen that helps a smooth cut further.

How many laser cutting types are there?

There is a variety of laser cutting depending on the tasks. These are:

Reactive Cutting

In this process, highly pressurized oxygen helps the flame to oxidize or burn the material. Usually, metal requires reactive Cutting to melt the target portion.

Fusion Cutting

Here the nitrogen helps the laser beam. The process starts by heating up the material and then gas is blown at the melting point.

Remote Cutting

This is a high-impact laser beam that proportionately evaporates the material, usually a thin sheet, and then performs cutting without any assistance of gas.

What is the difference between laser cutting and engraving?

Laser cutting refers to isolating a portion of the material by the laser beam. Laser engraving represents placing a pattern on any material by controlling the speed and power of the laser beam with computer-controlled laser software.

The depth of the cutting defines what is engraving and the marking. For example, if you extract a portion of wood or any board as per the design then it is called laser cutting.

When the laser beam helps to vapourize or melt a certain thickness (for example 6 mm) and makes the patterns identical then this a laser engraving.

A good example of laser marking can be placing a logo on a knife or leaving the company name on the parts.

What are the applications of a laser machine?

You can use a laser cutter to cut and engrave materials. Some lasers such as infrared and fiber laser machines can do metal marking. However, using the fiber laser, you can also remove metal rust or do welding.

There are different areas where people engage laser cutters. Some people use a low-capacity laser cutter to engrave on DIY things. There is also some small and medium-sized crafting business that prepares crafts, nameplates, customized gifts with laser engraving, and such. However, laser cutters also play a vital role in the industrial sector by cutting thin metals while making automobile parts and holograms them.

Nowadays, laser cutters are helping surgical sectors significantly by replacing scalpels. Usually, they vapourize human tissues and fix the diseases without needing any stitches.

Notably, lasers are the smartest alternative to hand engravings.

How many types of laser cutters are there?

In general, there are four types of laser cutters available in the market. These are COE, diode, fiber, and infrared laser.

Diode laser

Diode lasers are okay for small businesses but not suitable for working with heavy materials and large quantities around the year. Diode lasers can cut 5-8mm thick wood and 2-5 mm acrylic at max. However, it is not recommended for materials such as Brick, Rubber, Fabric, and Aluminium.

Normally, diode lasers use an electric source to generate a laser beam. In CO2 lasers, the laser light is produced by the reactive gas.

Here’s a list of best diode lasers for wood engraving.

CO2 laser

The CO2 laser is heavier than the diode laser with higher accuracy and speed. With a CO2 laser, you can cut and engrave a vast majority of materials and that is why these are quite expensive.

A C02 laser cutter is a machine that uses a beam of laser light to cut, engrave, and mark a variety of materials such as wood, metal, plastic, and glass. It works by focusing a high–powered laser beam on the material to be cut.

The spot size of a CO2 laser cutter typically ranges from 0.1 mm to 2.0 mm depending on the power and type of laser. A spot size refers to how precise a laser machine can cut the material. A shorter spot size is better for precise work.

Here are the differences between CO2 and fiber lasers.

Fiber laser

Fiber laser is mainly useful for metals that cannot be cut by CO2 lasers. For instance, Copper, Fiberglass, Nickel, and Silver cutting and engraving would require a fiber laser machine.

These lasers generate a beam of light that is focused and directed through a series of mirrors, lenses, and other optical components, allowing for precise and accurate cutting and engraving of materials. Fiber laser cutters are extremely versatile and can be used on a variety of materials, including metals, plastics, wood, glass, and paper.

There are two types of fiber lasers, one is an MOPA fiber laser and the other is a Q-switched fiber laser.

The only difference between a MOPA and a Q-switched fiber laser is controlling the pulse rate and pulse frequency. In short, with a MOPA fiber laser, you can control the laser beam’s pulse rate and pulse frequency which helps in handling sensitive materials and performing color engravings.

UV lasers are almost identical to fiber laser machines. UV lasers use ultraviolet light to achieve high precision and minimal thermal impact, making them ideal for delicate materials like plastics and glass. Fiber lasers, on the other hand, use optical fibers to amplify light, offering high power and efficiency, perfect for cutting and engraving metals and other tough materials.

Infrared laser

An infrared laser engraver stands out for being highly precise and powerful, traits that make it a top choice for metal and plastic engravings.

It’s preferred because the infrared wavelength cuts through materials CO2 or diode lasers can’t handle well, like certain plastics and metals.

The central hero of an infrared laser engraver is its wavelength, typically around 1064 nm. This shorter wavelength manages to be absorbed by metal surfaces rather than being reflected, a pivotal difference enabling marking actions that aren’t for CO2 (around 10,600 nm) or diode lasers in the visible spectrum.

How much does a laser cutter cost?

The cost of laser engravers ranges from USD 300 to USD 10,000, depending on factors like power, precision, capacity, portability, and scalability.

Entry-level diode laser machines typically cost between USD 200 and USD 1200, while more powerful CO2 lasers range from USD 2000 to USD 6000. Portable dual and infrared lasers fall in the USD 700 to USD 3000 range, and industrial fiber laser machines, which are more powerful and versatile, can cost between USD 6000 and USD 10,000.

Various factors influence the price of laser engravers, including the power of the laser source, engraving area size, precision, and additional features like autofocus and built-in cameras. The versatility of the machine in handling different materials, the durability and brand reputation, advanced cooling systems, safety features, and the quality of the software interface also contribute to the overall cost. Buyers should consider these aspects to make informed decisions that balance budget and performance.

What materials can you laser engrave?

You can engrave a variety of materials such as Metal, Plastics, Wood, Leather, fabrics, and paper. You need to set a different set of parameters per the material type. For instance, engraving metal would require high power and low line intervals.

While engraving wood, there will again be settings differences based on the types of wood. For example, basswood cutting takes less time than pinewood or balsa wood.

We will try to cover each of the materials one by one for a better understanding.

Here is a short list of the materials that you can laser engrave.

Engraving Metal

Metals are one of the most commonly laser-engraved materials due to their durability and wide range of applications. Common metals that can be laser engraved include:

• Aluminum: Ideal for anodized aluminum, producing high-contrast marks.
• Stainless Steel: Used in industrial applications for durable and precise markings.
• Brass: Offers a reflective surface suitable for detailed engravings.
• Copper: Engraving creates deep, clear marks suitable for electrical components.
• Titanium: Common in medical and aerospace industries for its strength and biocompatibility.
• Gold and Silver: Used in jewelry for intricate and personalized designs.

Engraving Leather

Leather engraving is tricky unless you know the right settings of your laser machine.

These are the challenges we faced while engraving leather workpieces:

• Each leather becomes unique due to nature and water composition that requires customized laser settings.
• Leather is sensitive to heat, and excessive heat during the engraving process can cause burning, warping, or discoloration.
• The natural texture and grain of leather can affect the consistency and clarity of the engraved design.
• The same leather workpiece can have different engraving colors due to temperature, air, and other factors.

But, we made the leather engraving easy!

How long does an engraved material last?

Laser engraving is a durable and efficient method for permanently marking items with precise and attractive designs.

The longevity of laser engravings largely depends on the material being engraved and the conditions it is exposed to. For instance, engravings on metals can last for decades, especially if the metal is durable and the engraving is deep.

However, softer metals, shallow engravings, and exposure to harsh environmental conditions can reduce durability. Similarly, engravings on glass, wood, and plastic also vary in longevity based on the quality of the material, the type of engraving, and exposure to elements like sunlight, moisture, and frequent handling.

By selecting appropriate materials and optimizing engraving settings, the durability of laser engravings can be significantly enhanced, ensuring they remain clear and legible for many years.

What are the differences between fiber lasers and infrared lasers?

Fiber lasers and infrared lasers often cause confusion due to their similar uses, but they differ significantly in wavelength and capabilities. Fiber lasers operate within a wavelength range of 780-1100 nm, making them powerful and versatile, ideal for industrial applications such as cutting, engraving, and welding metals.

They are known for their high precision, consistent quality, and low maintenance with a lifespan of up to 100,000 hours. In contrast, infrared lasers produce a fixed 1064 nm wavelength beam, are typically less powerful, more portable, and better suited for smaller-scale metal and plastic engraving projects.

When comparing efficiency and energy consumption, fiber lasers have high initial peak power and can reach up to 10,000 watts, suitable for deep and intricate metal engraving. Infrared lasers, although less precise and powerful, can reach up to 15,000 watts and are more cost-effective for small businesses due to lower initial and operational costs.

Fiber lasers offer superior precision and longevity, while infrared lasers are more portable and economical for smaller-scale tasks. Each type of laser has its niche, with fiber lasers excelling in industrial settings and infrared lasers being ideal for hobbyists and small businesses.

What are the differences between portable lasers and traditional lasers?

Portable engravers are usually more affordable, making them accessible to a broader range of users who need precise yet simple engraving capabilities for small-scale projects. In contrast, traditional lasers often come with advanced features like built-in cameras for precision alignment, superior ventilation systems, and more extensive software integration options. These characteristics make them suitable for professional artists, manufacturers, and businesses that need reliable, high-capacity engraving solutions capable of handling a wide variety of materials and complex tasks.

Portable laser engraving machines, like the xTool F1 and LaserPecker, are designed for convenience and mobility. These compact devices are typically lightweight, making them easy to transport and set up in various locations. They often feature user-friendly interfaces and Bluetooth or wireless connectivity, allowing for seamless operation from a smartphone or tablet. The emphasis on portability makes these machines ideal for hobbyists, small business owners, or DIY enthusiasts who require flexibility and ease of use.

In comparison, traditional laser engravers such as Glowforge and OMTech are generally more robust and powerful, designed for heavy-duty, professional-grade projects. These machines tend to be larger and stationary, requiring a dedicated workspace. They offer higher power outputs and larger working areas, allowing for the engraving and cutting of more substantial materials and more intricate designs.

What are the differences between galvo laser and traditional core X-Y lasers?

Galvo lasers use galvanometer mirrors to direct the laser beam quickly and accurately, making them ideal for high-speed engraving and marking applications. They excel in precision and speed, often used for intricate designs and fine details on various materials. The compact, moving mirror system allows for rapid changes in direction, resulting in faster processing times compared to traditional lasers.

In galvo technology, the laser beam direction is controlled by a mirror so that the laser diode does not need to move with the gantry.

Traditional core X-Y lasers, on the other hand, use a mechanical gantry system to move the laser head along the X and Y axes. This method provides a larger working area and is suitable for cutting and engraving larger materials. However, it is generally slower and less precise than galvo lasers due to the physical movement of the laser head. X-Y lasers are versatile and widely used for a range of applications, from hobbyist projects to industrial manufacturing.

Here’s why the galvo laser is faster than the traditional lasers.

What are the differences between laser marking, carving, and etching?

Laser carving, etching, and engraving, while often used interchangeably, have distinct differences. Carving involves deep, three-dimensional material removal, creating textured and sculpted designs, ideal for applications like sculptures and signage.

Etching is a surface-level technique that creates designs without significant depth, perfect for marking logos, serial numbers, and decorative patterns. Engraving strikes a balance, removing material to create detailed, precise designs with moderate depth, commonly used for personalizing items and industrial parts.

Each method varies in detail level, speed, durability, and visual impact, making them suitable for different applications and materials.

What is laser annealing?

Laser annealing is a metal marking process that alters the properties of the metal surface without melting or removing any layers, unlike laser engraving which involves material removal. This non-contact technique uses heat to change the metal’s atomic structure, creating designs or patterns, and can also produce color changes by varying temperatures.

Annealing is highly precise, environmentally friendly, and compatible with various metals like stainless steel and alloy steel. It’s often used for marking identification codes and creating color engravings, offering a fast and efficient marking solution. Unlike engraving, which is typically used for deeper, tactile designs, annealing provides a surface-level marking ideal for industries needing high precision and minimal material alteration.

What is 3d laser engraving?

3D laser engraving involves using powerful CO2, diode, or fiber lasers to melt or remove material both horizontally and vertically, creating three-dimensional designs. This process is similar to traditional wood carving with CNC machines but uses laser precision to achieve intricate details on various materials, including wood, metal, and plastics.

The technique starts with a 3D model converted into a grayscale image, which guides the laser on how deep to engrave. By adjusting the laser’s intensity and focus, detailed and realistic designs can be achieved, adding depth and texture. Key steps include preparing a 3D grayscale image, setting up the laser workspace, and adjusting parameters like power, speed, and line interval. Fiber lasers are preferred for metal engraving due to their specific wavelength compatibility.

Know about the engraving patterns

The engraving pattern plays a crucial role in laser engraving, influencing both the quality and efficiency of the work. Raster engraving and vector engraving are two primary techniques used in the process.

Raster engraving involves scanning the laser across the material in a series of lines, akin to how an inkjet printer works, making it ideal for detailed images and complex patterns. This method is effective for creating intricate designs with varying shades and depths. On the other hand, vector engraving follows the paths of vector graphics, which allows the laser to cut precise and continuous lines, making it perfect for outlines, text, and simple shapes.

The choice between raster and vector engraving impacts the speed, accuracy, and aesthetic outcome of the project. Properly selecting and optimizing the engraving pattern ensures high-quality results, reduces material waste, and enhances the overall efficiency of the laser engraving process.

What is subsurface laser engraving?

Subsurface laser engraving (SSLE) is a technique that uses high-intensity laser beams to create three-dimensional images within transparent or translucent materials by focusing below the surface to form microscopic fractures.

This method is commonly used for high-security identification cards, trophies, personalized gifts, and decorative architectural glass. SSLE offers high precision, durability, and flexibility but can be costly and time-consuming, and is limited to certain materials.

Typically, fiber and CO2 lasers are employed for this purpose, with considerations for laser power, wavelength, engraving area, accuracy, software compatibility, and maintenance.

Thinking about an engraving business?

What is lightburn, and how to set a canvas?

Setting accurate parameters in Lightburn is crucial for achieving the best results in CO2 laser engraving. Lightburn is a laser control software that allows users to adjust settings for optimal engraving, such as power, speed, scan interval, and line interval.

Properly setting the canvas ensures precise, clean, and high-quality cuts. For example, power settings must be adjusted according to the material, as excessive power can overburn, while insufficient power may fail to engrave effectively. Speed affects engraving accuracy, with slower speeds allowing deeper burns.

Scan and line intervals determine the resolution and clarity of the engraving, while the pass count and Z-offset are important for thicker materials and maintaining focus. Additionally, choosing the correct image mode and dithering pattern in Lightburn can greatly impact the detail and quality of the final engraving.

What are the pros and cons of a laser machine?

There are both pros and cons to using a laser cutter. For example, the advantages are:

• Easy to prototype
• Helpful for growing a crafting business
• Affordable than a CNC machine
• Batch processing

The disadvantages are:

• Consumes a lot of power
• Emits toxic fume
• Not all cutters can work on thicker materials

What is an air assist & how does it affect laser cutting?

A laser engraver air assist provides a steady stream of air to the laser head, enhancing precision and preventing debris accumulation during the engraving process.

It helps by oxygenating the cutting point, removing smoke and debris, cooling the laser head, and reducing the risk of material ignition. This results in cleaner, more accurate engravings, extending the laser’s lifespan and improving overall performance.

The below picture shows how air ensures the laser beam’s precision.

While essential for materials like rubber and fabric, which are prone to burning, air assist can sometimes be omitted for larger wood engravings.

Modern laser engravers often come with air assist kits, but compatibility and proper setup are crucial for optimal functionality. Using air assist ensures high-quality results and is generally beneficial for most engraving tasks.

How does rotary attachment empower a laser machine?

A rotary attachment is an accessory for laser engravers that enables the engraving of cylindrical or round objects by rotating them during the engraving process. This device holds the object and turns it smoothly to ensure the laser can engrave uniformly around the entire surface.

It is particularly useful for items like bottles, glasses, pens, and other round objects, allowing for precise and consistent engraving of text, logos, and designs around the object’s circumference.

Using a rotary attachment expands the versatility of a laser engraver, making it possible to customize a wider range of products. For instance, a rotary is a must for engraving tumblers.

What are the common problems of laser machines?

Laser engravers sometimes give a hard time. If you cannot troubleshoot the problem by quickly, it will cost your time and money.

Typical problems are:

• Unexpected power shut
• No laser light
• Gantry not moving
• Lack of precision
• inaccurate resolution

This is important for you to know the solution to all engraving problems so that your laser productivity is not interrupted.

How a laser cutter is different from a CNC machine?

A CNC (Computer Numerical Control) cutter and a laser cutter are both tools used for cutting and engraving materials, but they operate differently and are suited for different tasks.

A CNC cutter uses a rotating cutting tool to mechanically remove material from a workpiece based on a pre-programmed design. It is highly versatile, capable of working with a variety of materials like wood, metal, plastic, and composites, and can perform tasks like cutting, drilling, milling, and carving.

A laser cutter, on the other hand, uses a high-powered laser beam to cut or engrave materials by vaporizing or melting them. It offers precision and speed, making it ideal for intricate designs and fine details. Laser cutters are commonly used with materials like wood, acrylic, plastics, fabric, and thin metals.

Why laser cutters outweigh plasma-cutting machines?

A laser cutter uses a focused laser beam to melt, burn, or vaporize material, allowing for precise and intricate cuts, suitable for materials like wood, plastic, and thin metals.

A plasma cutter, however, uses a high-velocity jet of ionized gas (plasma) to cut through electrically conductive materials, making it ideal for cutting thicker metals with faster cutting speeds but less precision compared to laser cutters. Here we differentiated both broadly.

Frequently Asked Questions