Expert Guide to Laser Cutting Acrylic: Techniques, Best Practices, and Top Machines
Acrylic, commonly known as plexiglass, is a versatile and visually appealing material used across various industries. Its popularity in both commercial and creative projects is due to its clarity, strength, and ease of fabrication. Using a laser cutter is one of the most effective and exact ways to cut acrylic.
In this blog, we will delve into the intricacies of laser cutting acrylic, explore the different types of acrylic, identify the best laser machines for the job, and provide project inspiration to help you get started.
Is It Possible to Cut Acrylic Using A Laser Cutter?
Yes, acrylic can be effectively cut with a laser cutter, particularly using a CO2 laser.
The laser's precision allows for smooth, clean cuts and detailed engravings. This method is highly efficient, minimizing waste and ensuring a high-quality finish that typically requires little to no post-processing.
Acrylic’s responsiveness to laser cutting makes it ideal for applications ranging from signage and displays to intricate jewelry and decorative items.
How Acrylic Laser Cutting Works
Laser cutting acrylic involves focusing a powerful laser beam onto the surface of the material.
The laser is guided by a design file, which dictates the path of the cut. The laser beam's intense heat vaporizes the acrylic along its path, creating precise cuts.
For engraving, the laser settings are adjusted to vaporize only the surface layer, creating detailed designs without cutting through the material.
Varieties of Acrylic for Laser Cutting
There are two primary types of acrylic: cast acrylic and extruded acrylic. Each type has distinct properties that affect its suitability for different laser-cutting applications.
When laser cutting acrylic, cast acrylic is the superior choice for 95% of projects. While extruded acrylic is cheaper and melts quickly, cast acrylic is always better for cutting because it provides a beautiful, clean, flame-polished cut edge and a bright, frosted white engraving.
- Cast Acrylic: This variety is produced by pouring liquid acrylic into molds. It is known for its superior optical clarity and quality when engraved. Cast acrylic yields a polished edge when cut, making it perfect for applications requiring a smooth finish.
- Extruded Acrylic: This type is produced by pressing acrylic through rollers to achieve the desired thickness. While it is more cost-effective and easier to cut, extruded acrylic does not offer the same high-quality finish as cast acrylic. It is better suited for uses where edge quality is not as important.
Cast vs. Extruded: Which Acrylic Is Better For Cutting?
| Feature | Cast Acrylic (Highly Recommended) | Extruded Acrylic (Use with Caution) |
| Engraving Look | Bright, frosted white with great contrast. | Dull grey, gummy, and looks melted. |
| Cut Edge Finish | Smooth, glass-like, "flame-polished" edge. | Can leave a hazy, melty, or uneven edge. |
| Smell | Smells sweet but strong when cut. | Extremely pungent and sharp; smells like burning vacuum belts. |
| Best For... | Signage, jewelry, layered art, and engraving. | Production parts where the edges are hidden. |
To know more differences between these two types of acrylic, read this article.
What Laser Machine Can Cut Acrylic?
CO2 lasers are the optimal option for cutting acrylic. These lasers function at a wavelength that acrylic easily absorbs, allowing for efficient cutting.
Is Acrylic Cutting Possible with a Diode Laser?
Although diode lasers can cut acrylic, they come with notable limitations. Diode lasers, especially those with blue light, struggle with clear and blue acrylic due to the wavelength matching the color of the material, preventing absorption.
Diode lasers are better suited for dark, opaque acrylics. For most acrylic cutting needs, CO2 lasers are a more reliable choice.
Choosing the Right Laser Type For Cutting Acrylic
The type of laser machine you own dictates what kind of acrylic you can work with:
- CO2 Lasers: The ultimate choice for plastic. Acrylic directly absorbs the infrared light from CO2 lasers, allowing them to slice through clear, translucent, and opaque acrylic effortlessly.
- Diode Lasers (Visible Blue Light): Diode lasers cannot cut clear or transparent acrylic because the blue light passes straight through it. They can only cut dark or opaque colors (especially black) that successfully absorb the light energy.
Cutting Acrylic Settings
Because every laser machine has a slightly different true power output, you should never blindly trust a static chart. Instead, use the baseline settings below to begin your testing.
Which OMTech CO2 Laser Machine Is Best for Cutting Acrylic?
OMTech offers a wide range of CO2 laser machines, from compact desktop models and mid-range power systems to high-power industrial units. The most suitable model depends entirely on your specific needs.
If you only need to engrave and cut small acrylic items like keychains or jewelry, our desktop models are sufficient. For instance, the OMTech Polar Lite desktop CO2 laser features a 20" × 12" processing area and supports cutting up to 1-inch thick acrylic.
For those with larger projects, you should consider our larger-scale CO2 models, such as the Maker and Pronto series. Beginners can start with the Maker series, which offers excellent results at an affordable price. If you run a small business and require better performance and quality, the Pronto series is your choice.
Finally, if your goal is to cut thicker and larger acrylic sheets with greater efficiency, the Pro series is recommended. Their industrial configuration makes them a powerhouse for heavy-duty acrylic cutting.
Baseline Settings for Cutting 1/8" (3mm) Acrylic
| Laser Type | Common Machines | How It Performs on Acrylic | Recommended Starting Settings |
| 40W–50W CO₂ Laser | OMTech K40, Beamo | CO₂ lasers emit infrared light that is readily absorbed by acrylic, producing smooth, flame-polished edges with clean cuts. | Power: 60–70%Speed: 3–5 mm/s |
| 60W–80W CO₂ Laser | OMTech Pronto, Thunder Laser | Ideal for faster cutting while maintaining polished edges and excellent cut quality on clear, colored, and opaque acrylic. | Power: 60–65%Speed: 8–12 mm/s |
| 100W+ CO₂ Laser | OMTech Pronto, Boss Laser | Designed for high-speed production and thicker acrylic sheets, delivering clean cuts with fewer passes. | Power: 55–65%Speed: 15–20 mm/s |
| 10W Diode Laser | xTool D1 Pro, Ortur, Atomstack | Diode lasers use visible blue light, which passes through clear, white, and blue acrylic. They can effectively cut only dark, opaque acrylics such as black or dark red. | Power: 100%Speed: 1–3 mm/s |
| 20W Diode Laser | xTool S1, Atomstack, Ortur | Higher-powered diode lasers cut dark acrylic faster than 10W models but still cannot process transparent or light-colored acrylic effectively. | Power: 100%Speed: 4–5 mm/s |
How to Laser Cut Acrylic
Here’s a detailed guide to laser cutting acrylic using the OMTech CO2 laser cutter:
- Acrylic Sheet Placement: Ensure the acrylic sheet lies flat on the workbed to avoid any distortion or uneven cuts.
- Import Your Design: Upload your design file into the LightBurn software. This software is compatible with the OMTech laser cutter and provides a user-friendly interface for design management.
- Adjust the Cutting Settings: Use the preset "Material EasySet Library" for optimal settings or manually adjust parameters such as power, speed, and frequency based on the acrylic type and thickness.
- The Cutting Process: Initiate the cutting process once the settings are configured. Supervise the procedure to guarantee accuracy and make any needed modifications.
- Finishing Touches: After cutting, remove the acrylic piece and peel off any protective film. Inspect the edges and clean if necessary.
What Laser Settings Should Be for Laser Cutting Acrylic?
Choosing the right settings is essential for obtaining optimal results. Here are some basic recommendations:
- Power: A general guideline for cutting acrylic is to use 10 watts of laser power per millimeter of material thickness. For instance, a 10mm thick acrylic sheet requires a 100W laser for optimal cutting. But a 60W OMTech laser cutter can also handle it.
- Speed: Adjust the speed based on the power and thickness of the acrylic. Higher speeds are suitable for thinner materials, while thicker acrylic requires slower speeds to ensure a clean cut.
- Frequency: For Cast Acrylic materials, a frequency range of 5,000-20,000 Hz is recommended. For Extruded Acrylic materials, a maximum frequency of 5,000 Hz should be used.
Learn More: Laser Settings for Different Materials
How to Run a "Material Test Matrix" To Determine the Best Settings For Cutting Acrylic
There is one golden rule for laser cutting acrylic: always cut acrylic in a single pass. Attempting multiple passes will reheat the material and cause the edges to melt, warp, and bubble into a sticky, ruined mess. So, to avoid guesswork, what you must do is run a materials test matrix to determine what your settings should be before cutting acrylic.
Here’s what to do:
- Download or generate a Laser Test File in your laser software (like LightBurn). This file automatically cuts a small grid of squares.
- Take note that each square uses a slightly different combination of speed and power.
- Look for the block that drops right out of the sheet cleanly with the smoothest, least-melted edge. That is your machine's perfect setting!
Top Settings Tweaks and Adjustments For Laser Cutting Acrylic
1. Air Assist: Low vs. High
For cutting acrylic, keep air assist on but low. You need just enough air pressure to blow away hazardous chemical gases and protect your lens from smoke. If your air pressure is too high, it will cool the molten plastic too fast, creating a rough, frosty, wavy edge instead of a glass-smooth finish.
For acrylic engraving: Keep air assist high to quickly blow the white, powdery acrylic residue off the surface before it can melt back down onto your clean design.
2. Protect Your Tube Life
Never set your software to 100% power if you own a glass CO2 laser tube. Running a CO2 tube at absolute maximum power will dramatically shorten its lifespan or burn it out early. Keep your maximum cutting power capped at 75% to 80% and slow your speed down to compensate.
3. Mind the Kerf
The laser beam melts away roughly 0.15mm of material as it cuts (called the "kerf"). If you are cutting interlocking puzzle pieces or boxes, remember to use "Kerf Compensation" in LightBurn so your finished parts press-fit together perfectly without rattling.
Here is a video for you to know more about laser cutting acrylic.
Inspiring Acrylic Projects Using Laser Cutting
Laser-cutting acrylic unlocks limitless creative opportunities. Here are some inspiring project ideas:
- Acrylic Earrings: Design unique and fashionable jewelry items.
- Acrylic Signs: Create custom signs for businesses or personal use.
- Acrylic Awards: Produce personalized awards for various events.
- Acrylic Keychains: Make custom keychains in different shapes and sizes.
- Acrylic Ornaments: Craft ornaments for holidays and special occasions.
- Acrylic Wedding Invitations: Design elegant and distinct wedding invitations.
- Acrylic LED Lights: Create LED lights for decorative lighting.
- Acrylic Place Cards: Make stylish place cards for events and celebrations.
- Acrylic Cake Toppers: Personalize cake toppers for birthdays and other celebrations.
Pro Tips For Laser Cutting Acrylic
1. Use the Most Suitable Settings
- Lower power, faster speed: To avoid a raised, melted ridge around your cut line, cut as quickly as possible without sacrificing accuracy. If the material gets too hot, it warps and deforms.
- Elevate the sheet: Do not lay thin acrylic flat on a solid metal bed. Use pins, standoffs, or a blade bed to lift the material. This allows heat to dissipate and prevents flashback marks on the underside of your piece.
2. Masking is Non-Negotiable
- Leave the paper on: Keep the original protective paper masking on the acrylic while laser cutting. It prevents smoke stains and surface flare-ups.
- Use transfer tape: If your acrylic comes with clear plastic masking (which melts terribly), peel it off and apply a high-quality medium-tack paper transfer tape before cutting.
- Use the duct tape trick: If you cut an intricate design and the tiny bits of paper mask are stuck, press a strip of heavy-duty duct tape or Gorilla tape firmly over the design and peel it back to pluck all the tiny paper pieces out effortlessly.
3. Design for Precision and Assembly
- Account for kerf: The laser beam vaporizes a tiny bit of material (the "kerf") as it cuts. If you are creating a puzzle fit or inlay, use digital calipers to measure your cut pieces and adjust your software's kerf offset for a tight, friction fit.
- Mirror your inlays: Because laser beams have a slight V-shape taper, mirror your inlay design and cut it from the back side. This allows the tapered edges of the two pieces to wedge together perfectly with zero gap.
- Watch out for glue cracks: Standard superglue (cyanoacrylate) or harsh solvent cleaners can cause micro-cracks (crazing) in the plastic. For joining acrylic, use specialized acrylic solvents like Weld-On 4, which weld the plastic chemically.
Trusted Acrylic Suppliers
If you are looking for reliable material, it is best to skip generic Amazon bundles and order from dedicated suppliers:
- TAP Plastics: Great overall selection of sizes, colors, and cuts.
- MakerStock: Sells sheets specifically sized to fit popular hobby lasers like Glowforge.
- Johnson Plastics Plus: High-quality laserable materials and reliable brands like Rowmark.
- Canal Plastic Center: The go-to spot for specialized aesthetics like iridescent, neon, mirrored, or translucent tones.
Conclusion
Laser-cutting acrylic with the right equipment and settings can produce professional and precise results.
The OMTech laser cutter stands out as an excellent choice for working with acrylic, offering the necessary power, precision, and user-friendly features. Whether you're a hobbyist or a professional, this machine can turn your creative ideas into reality.
FAQs about Laser Cutting Acrylic
How thick can a laser-cut acrylic be?
The thickness a laser can cut depends on its power. A 60W CO2 laser can cut up to 10mm thick acrylic, while a 100W laser can handle even thicker materials.
How do I clean acrylic after laser cutting?
Use a non-abrasive fabric like a lint-free or microfiber cloth. For dirty surfaces, use a small amount of mild detergent and avoid applying excessive pressure.
Is all acrylic available to laser cut?
While most acrylics are suitable for laser cutting, variables such as color and type can influence the process. Always test the specific acrylic you plan to use to ensure compatibility with your laser cutter.
What laser power is needed to cut acrylic?
Generally, acrylic needs 10 watts of power for each millimeter of thickness. For instance, a 10mm thick acrylic sheet is optimally cut with a laser of 100W or higher.
Is it possible to laser cut acrylic without the protective film on?
Removing the protective film before laser cutting is usually advised to prevent difficult cleanup afterward. For laser cutting, the film can be left on, especially for large projects, but can be removed for small cuts.
Do I leave the paper on acrylic when laser cutting?
No, you should not leave the paper on the acrylic during laser cutting.
The paper can catch fire under the intense heat of the laser, potentially damaging your project and possibly causing a fire hazard.
It's best to remove any paper or masking material before starting the laser cutting process.
If you're concerned about the acrylic melting or warping during the cutting process, you can consider using a laser cutting mask or a water table to help dissipate heat and prevent damage.
