Plastic Laser Cutting Service 101: The Complete Guide

Published by Worthy Hardware at December 12, 2024

What Is Plastic Laser Cutting?

Plastic laser cutting is a precise manufacturing process that uses a laser to cut or engrave plastic materials. This technique is widely used for its accuracy, clean edges, and ability to cut complex shapes with minimal material waste.

The process starts with a computer-aided design (CAD) file, which contains the exact dimensions and patterns for the desired cut. Using this CAD file, the laser cutting machine follows the design to cut the plastic material precisely as specified.

The machine typically uses a CO2 laser, which is one of the most common types of lasers for cutting plastics. The CO2 laser emits a focused beam of light that melts or vaporizes the plastic at the cutting point. This high-powered beam is controlled by the machine’s computer system, which ensures that the cut is smooth and accurate. The precision of the CO2 laser allows for tight tolerances, making it ideal for both simple and intricate designs.

Advantages of Plastic in Laser Cutting

Precision and Accuracy in Cuts: Laser cutting offers highly accurate cuts, ensuring that designs are replicated with extreme precision.
Clean Edges and Minimal Waste: The laser beam melts the plastic with minimal kerf (the width of the cut), resulting in smooth edges and less material waste.
Customization Capabilities: With laser cutting, you can easily customize shapes, sizes, and designs, allowing for limitless creativity in product development.
Quick Turnaround Time: Laser cutting is fast, enabling quicker production times and faster delivery of custom orders.
Ability to Cut Complex Shapes: The laser’s precision makes it possible to cut intricate, complex shapes that would be difficult or impossible to achieve using other methods.

Disadvantages of Plastic in Laser Cutting

Material Melting and Burn Marks: Some plastics may melt or develop burn marks at the edges when exposed to the high heat of the laser, affecting the appearance of the cut.
Limited Thickness Options: Not all plastics can be cut at all thicknesses. Laser cutting is generally more effective on thinner materials, and thicker plastics may require more power or specialized techniques.
Risk of Toxic Fumes: When cutting certain types of plastic, such as PVC, toxic fumes can be released. Proper ventilation and fume extraction systems are essential to ensure a safe working environment.
High Energy Consumption for Some Plastics: Laser cutting, especially for thicker plastics, can consume a significant amount of energy, making it less cost-effective for larger production runs or materials that are difficult to cut.

What Kind of Plastic Can Be Laser Cut?

Laser cutting works best with certain types of plastics, and it’s important to understand the differences between thermoplastics and thermosets when selecting a material.

Polycarbonate: A tough, impact-resistant material with excellent clarity, polycarbonate is ideal for both functional and decorative parts.
Acrylic (PMMA): Acrylic is one of the most popular plastics for laser cutting due to its ease of cutting, smooth edges, and bright finish. It’s often used for signage, displays, and decorative items.
Polyimide: Known for its high heat resistance, polyimide is used in applications that require both high-performance and durability, such as aerospace components.
Delrin (Polyoxymethylene): Delrin is a strong, durable plastic that holds up well under mechanical stress, making it a great option for precision parts and components.
Polyesters (PET, Mylar, PETG): These plastics are known for their strength, clarity, and resistance to chemicals. PETG, in particular, is popular for laser cutting due to its toughness and ease of fabrication.
Polypropylene: Lightweight and flexible, polypropylene is a versatile plastic used in a variety of applications, including packaging, automotive parts, and medical devices.

What is the Best Laser Cutting Plastic?

The “best” plastic for laser cutting depends on your specific needs, but generally, acrylic is considered one of the top choices due to its combination of ease of cutting, aesthetic quality, and versatility. It cuts smoothly, provides clean edges, and offers a high-quality finish, making it ideal for projects ranging from signage to decorative items.

However, if durability and impact resistance are your priorities, polycarbonate is an excellent option. It’s tougher and more resistant to cracking compared to acrylic, though it can be a bit more challenging to cut due to its higher melting point.

For applications where flexibility and chemical resistance are crucial, polypropylene might be the best fit. It’s ideal for products that need to withstand wear and tear, like packaging materials or automotive parts.

Can Any Plastic Be Laser Cut?

Not all plastics are suitable for laser cutting. While thermoplastics like acrylic, polycarbonate, and PET are ideal for laser cutting due to their ability to melt and re-solidify, thermosetting plastics (like epoxy or phenolic) are not. These materials harden permanently when heated, making them unsuitable for laser cutting.

Additionally, some plastics release harmful fumes when cut, such as PVC, which emits toxic chlorine gas. Always check the material’s compatibility with laser cutting before starting the process, and ensure proper ventilation and safety measures are in place.

What Laser Technology is Best to Cut Plastic With?

The best laser technology for cutting plastic is the CO2 laser. Its high precision, versatility, and ability to cut through various plastic types make it the go-to choice for most applications.

Applications of Plastic in Laser Cutting

Signage and Displays
Automotive Parts
Medical Devices and Equipment
Packaging
Prototyping and Product Development
Decorative Items and Gifts
Electronic Components
Industrial Components
Engraving and Personalization
Window and Door Components

What Thickness of Plastic Can Be Laser Cut?

The thickness of plastic that can be laser cut typically ranges from 0.1 mm to 25 mm. Thinner plastics (under 3 mm) are easier to cut with more precision, while thicker plastics may require higher-powered lasers and may not achieve the same clean edges. The specific material also affects the cutting capabilities, with some plastics like acrylic being cut at greater thicknesses compared to others like polypropylene.

Laser Cutting vs. Laser Engraving for Plastic

Feature	Laser Cutting	Laser Engraving
Purpose	Cuts through the material to create shapes or designs	Etches or marks the surface of the material
Depth of Impact	Can cut through the entire thickness of the plastic	Affects only the surface layer of the material
Precision	High precision, clean edges	High precision, detailed surface designs
Material Removal	Material is removed (cutting through)	Material is vaporized or scorched for surface marking
Edge Quality	Smooth, clean edges with minimal burn marks	Surface is etched, often with a slight burn effect
Speed	Slower due to the cutting process	Faster, as it only alters the surface
Uses	Producing parts, custom shapes, and prototypes	Logos, text, serial numbers, and decorative patterns
Common Materials	Acrylic, polycarbonate, PET, PVC	Acrylic, wood, leather, anodized metals
Material Thickness	Suitable for various thicknesses (up to 25 mm)	Works best on thin materials

Laser Cutting vs. CNC Machining for Plastics

Feature	Laser Cutting	CNC Machining
Process Type	Uses a focused laser beam to cut or engrave the material	Uses rotating cutting tools to carve the material
Precision	High precision, ideal for intricate and detailed designs	High precision, especially for complex 3D shapes
Cutting Speed	Faster for simple cuts and large production runs	Slower, particularly for detailed cuts and complex shapes
Material Waste	Minimal material waste due to precise cutting	Can generate more waste, especially with large parts
Edge Quality	Smooth edges with little to no burrs or roughness	Edges may need further finishing due to tool marks
Tooling Costs	Lower tooling costs, no need for special tools	Higher tooling costs due to specialized cutting tools
Thickness Capability	Works well with thinner plastics (0.1 mm to 25 mm)	Suitable for thicker plastics, including high-density materials
Complex Shapes	Ideal for cutting complex, intricate shapes	Better for cutting thicker, more rigid shapes
Material Types	Works well with most plastics (acrylic, polycarbonate, PVC)	Works well with a wide range of plastics and composites
Post-Processing	Requires minimal post-processing for most materials	May require additional post-processing (deburring, polishing)

Waterjet Cutting vs. Laser Cutting for Plastics

Waterjet cutting and laser cutting are both popular methods for cutting plastics, but they each have their own strengths and are suited to different applications.

Waterjet Cutting uses a high-pressure stream of water mixed with abrasive particles to cut through plastic. It is highly effective for cutting thick materials, as it doesn’t generate heat, preventing any warping or melting of the plastic. This makes waterjet cutting ideal for heat-sensitive materials that might be damaged by the high temperatures produced by lasers.

Waterjet cutting can also be used on a wide range of plastic types and thicknesses, from thin sheets to several inches thick. However, it tends to have a wider cut kerf compared to laser cutting, meaning it can produce less precision in intricate designs.

Laser Cutting, on the other hand, uses a focused laser beam to melt, burn, or vaporize plastic. It is known for its precision, clean edges, and ability to cut intricate shapes quickly. Laser cutting is best for thinner plastics and applications that require high accuracy.

However, it can be less effective for thicker plastics, which may need higher-powered lasers to cut through. Laser cutting can also produce heat-affected zones (HAZ), leading to potential warping or discoloration, especially with heat-sensitive plastics like acrylic.

In summary, waterjet cutting is better for cutting thicker plastics and heat-sensitive materials, while laser cutting excels at cutting thinner plastics with high precision and speed. The choice between the two methods depends on the material thickness, design complexity, and tolerance requirements of your project.

Laser Cutting vs. Die Cutting

Feature	Laser Cutting	Die Cutting
Process Type	Uses a focused laser beam to cut or engrave the material	Uses a steel die to stamp and cut the material
Precision	High precision, ideal for intricate and detailed designs	Can be precise, but typically less detailed than laser cutting
Cutting Speed	Faster for simple designs and custom cuts	Faster for mass production of simple shapes
Edge Quality	Smooth, clean edges with minimal burn marks	Edges may be less clean, can require additional finishing
Setup Time and Cost	Low setup costs, quick to change designs	High setup costs, requires a custom die for each design
Material Flexibility	Works with a wide variety of materials and thicknesses	Best suited for thin to medium thickness materials
Thickness Capability	Effective for thinner plastics, up to 25 mm	More suitable for thicker materials, often up to 6 mm
Waste	Minimal waste due to precise cutting	Can generate more waste, depending on the layout of the design
Complexity of Designs	Ideal for complex, intricate shapes and designs	Best for simple shapes or large quantities of the same design
Production Volume	Slower for high-volume production	Faster for high-volume production of identical parts
Post-Processing	Minimal post-processing needed	May require additional post-processing, like trimming or smoothing edges

Post-Cutting Plastic Treatment and Finishing

After laser cutting plastic, some treatments and finishing processes may be necessary to enhance the appearance, functionality, or durability of the final product. Here’s an overview of common post-cutting treatments for plastic:

1. Edge Polishing

Laser cutting can leave rough or slightly burned edges, especially with materials like acrylic. Edge polishing involves smoothing these rough edges for a cleaner, more professional finish. This can be done using various methods, including flame polishing, which uses a flame to melt the edge slightly for a smooth, glossy finish.

2. Cleaning

After cutting, plastics may have residue, soot, or dust on the surface. Cleaning is important for removing these particles. It can be done using a variety of methods, such as air-blasting, using wipes or cloths, or in some cases, ultrasonic cleaning to remove contaminants without damaging the material.

3. Deburring

For some plastics, deburring is necessary to remove any small burrs or sharp edges that may remain after cutting. This is often done with specialized tools or manually to ensure the product is safe to handle and has a high-quality finish.

4. Engraving or Marking

Post-cutting engraving or marking is often done to add branding, labels, or part numbers to the cut plastic. Laser engraving is commonly used for this, but other methods, such as inkjet or mechanical engraving, may also be applied depending on the material and the application.

5. Heat Treatment

Some plastics, especially acrylic, can undergo heat treatment after cutting to relieve internal stresses caused by the laser process. This can involve placing the cut plastic in an oven at a specific temperature for a set amount of time to make the material more stable and less prone to warping or cracking.

6. Surface Coating or Painting

To improve the aesthetics or functionality of the product, surface coating or painting can be applied. For example, plastics like acrylic or polycarbonate can be spray-painted or coated with protective layers to enhance color, durability, and resistance to UV light or abrasion.

7. Assembly

In many cases, post-cutting assembly is required if the plastic parts are components of a larger product. This may involve joining different plastic parts together using adhesives, screws, or other fastening methods.

8. Polishing or Varnishing

After cutting, plastics such as acrylic can be polished or varnished to improve clarity and shine. This is commonly done for applications like displays, lighting panels, or signs where a glossy finish is essential.

9. Thermoforming or Bending

For some applications, thermoforming or bending of the cut plastic parts may be required. This involves heating the plastic to make it pliable, allowing it to be shaped or molded into the desired form.

10. UV Coating

For plastics exposed to outdoor environments, applying a UV protective coating after cutting helps prevent the material from yellowing or degrading over time due to exposure to sunlight.

Conclusion

At Worthy Hardware, we specialize in precision laser cutting services for a wide range of plastic materials. If you’re ready to bring your designs to life with the highest quality cuts and finishes, don’t hesitate to reach out. Contact us today for a consultation or to request a quote!

FAQ

Q: What types of plastics can be laser cut?
A: Common plastics like acrylic, polycarbonate, PVC, and polypropylene can be laser cut. However, some thermoset plastics are not suitable for laser cutting.

Q: How thick can plastic be for laser cutting?
A: Laser cutting works well for plastic materials ranging from 0.1 mm to 25 mm in thickness, depending on the type of plastic.

Q: Can laser cutting create intricate designs on plastic?
A: Yes, laser cutting is highly precise and can easily create detailed, intricate designs on plastic with smooth edges.

Q: Is laser cutting faster than CNC machining for plastic?
A: Yes, laser cutting is typically faster for simple cuts and smaller production runs compared to CNC machining, especially for thinner materials.