Is Acrylic Suitable for Laser Cutting and Engraving?

Acrylic, also known as plexiglass, is a visually striking material used in a wide range of products. Laser cutting is a popular method for shaping acrylic because it delivers clean, smooth cuts. Additionally, laser engraving creates a frosted etching effect, adding a beautiful contrast to clear acrylic surfaces.

Acrylic is an extremely versatile material which provides great results when being laser cut or laser engravedBoth extruded and cast acrylic can be laser cut, but they behave differently during the process. Extruded acrylic may develop a slight burr on the edges after cutting, while cast acrylic produces a much smoother edge. Depending on the power of the laser, acrylic can be cut up to a thickness of 25mm while maintaining a clean, square edge. Clear cast acrylic is often preferred for creating awards and plaques because, when engraved, it turns a frosty white color, resulting in a beautiful finish. However, some colors of acrylic may not respond well to laser cutting due to how the pigments or dyes interact with heat. Edge discoloration can often be minimized by adjusting the laser settings, such as cutting speed, air flow, and power levels.

What Laser Cutter Will Cut Acrylic?

CO₂ lasers

CO₂ lasers are the best machines for cutting and engraving acrylics. This is because the CO₂ laser's wavelength (9.6 to 10.6 micrometers) is readily absorbed by acrylics, causing the plastic material to vaporize where the laser hits it.

CO2 laser cutters emit laser beams in the infrared region, which can be absorbed by acrylic of all colors, making them the most suitable laser type for cutting acrylic. Those with sufficient power can easily cut acrylic in a single pass.

How Laser Cutting Acrylic Works

Laser cutting acrylic involves focusing a powerful laser beam, guided by a design file, onto the acrylic surface. The heat from the laser quickly vaporizes the material along the designated path, transforming the acrylic sheet into the desired shape.

In addition to cutting, the same laser beam can also be used for engraving. By adjusting the settings, the laser can vaporize only a thin layer from the acrylic surface, leaving behind an intricate engraved design.

Can a Diode Laser Cut Acrylic?

A diode laser can cut acrylic, but there are certain limitations depending on the color of the material. Generally, diode lasers can cut some dark, opaque acrylics. However, blue acrylic cannot be engraved or cut with a blue-light diode laser, as the material doesn't absorb the laser beam due to the matching color. Additionally, diode lasers are not capable of engraving or cutting clear acrylic.

Types of Acrylic for Laser Cutting

Acrylic is typically divided into two types based on its manufacturing process: Cast Acrylic and Extruded Acrylic.

Cast acrylic is made by pouring molten acrylic into a mold, which defines the shape, size, and thickness. Extruded acrylic, on the other hand, is produced by mechanically pressing the acrylic until it reaches the desired thickness.

Cast or Extruded Acrylic for Laser Cutting?

Both cast and extruded acrylics can be effectively cut with a laser, but cast acrylic is preferable for achieving a cleaner, polished edge. For laser engraving, cast acrylic is recommended due to its sharper, higher-quality engravings.

If you prioritize a clean edge finish and high-quality engravings, cast acrylic is the better choice. However, if cost is a primary concern, extruded acrylic can be a suitable alternative.