How to Laser Engrave and Cut Polycarbonate

Polycarbonate (PC) is a very versatile material. It is a thermoplastic polymer with good mechanical properties and durability. It is sometimes called Lexan, Hyzod, Makrolon, or Tekanat. Those are all brand names for the same material. Laser cutting polycarbonate is able to be easily done with a 10.6 µm CO₂ laser cutter. However, one has to be aware that the laser beam is able to discolor the PC sheet. Generally, the thinner the sheet is, the better the results are. For laser engraving of PC, a fiber laser is the best choice. It must have the same wavelength as the CO₂ laser cutter (1064 nm). The fiber laser is going to leave black markings on the PC if done correctly. These markings are permanent and have excellent contrast. For example, a very suitable laser system for laser cutting of PC is the LS series from Boss Laser.

The optimum power, speed, focal length, and airflow level strongly depend on the thickness of the PC sheet that must be cut or engraved. The cutting edges of the PC sheet are going to get discolored.

Listed below are the things that must be done to get the best results.

The resolution of the file must be at least 400 dpi (500-600 dpi is even better).
Choose the right laser power – about 20 W for cutting and 15 W for engraving must be sufficient.
Focus the laser beam onto the surface to create black-colored engraving marks.
Choose the right laser speed – about 7-12 mm/s. Usually, lower speeds produce better results.
Work with sufficient airflow as PC fumes quite strongly when laser cut or engraved.

Table of Contents

How to Laser Cut and Engrave Extruded Polycarbonate?

Listed below are the eight steps to laser cut and engrave extruded polycarbonate.

Get the artwork ready. Use design tools like Adobe Illustrator or CorelDRAW to create the artwork in a vector format. Make sure the artwork is the suitable size and that the cutting and engraving settings are set correctly.
Install the laser cutter. Follow the manufacturer’s instructions while setting up the laser cutter. Make that the power, speed, and frequency parameters are adjusted to the extruded polycarbonate’s characteristics.
Setting up the material. Clamps or other holding mechanisms must be used to fix the extruded polycarbonate to the laser bed so that it doesn’t move while being cut and engraved.
Focus the laser. The laser must be focused after being adjusted at the proper distance from the material. It is crucial to do this to guarantee that the laser beam is focused and creates exact cuts.
Test cut. Use a scrap piece of extruded polycarbonate to do a test cut to make sure the laser settings are accurate and deliver the intended results.
Laser cut. Following the artwork’s design and cutting specifications, laser cut the extruded polycarbonate after ensuring the correct settings.
Laser engrave. Set up the laser for engraving and follow the design and engraving settings in the artwork if wanted to engrave the extruded polycarbonate.
Remove and clean the final product. Extruded polycarbonate must be carefully removed from the laser bed when cutting and engraving are accomplished, and the end product must be thoroughly cleaned of any dirt or residue.

How to Laser Cut and Engrave Cast Polycarbonate?

Listed below are the eight steps to laser cut and engrave cast polycarbonate.

Assemble the artwork. Produce the artwork in vector format using design tools such as Adobe Illustrator or CorelDRAW. Ensure the artwork is suitably sized and has the correct cutting and engraving settings.
Set up the laser cutter. Follow the manufacturer’s instructions for setting up the laser cutter. Make that the power, speed, and frequency parameters are adjusted to match the qualities of the cast polycarbonate.
Place the material. Secure the cast polycarbonate to the laser bed with clamps or other holding mechanisms to prevent it from moving during the cutting and engraving.
Set the laser focus to the appropriate distance from the material. Ensuring that the laser beam is focused and generates clean, accurate cuts is essential.
Test cut. Using a scrap piece of cast polycarbonate, do a test cut to check the laser settings are proper and provide the required results.
Following the design and cutting specifications in the artwork, laser cut the cast polycarbonate after making sure the laser settings are proper.
Set up the laser for engraving and follow the design and engraving settings in the artwork if wanted to engrave the cast polycarbonate.
The cast polycarbonate must be gently removed from the laser bed when the cutting and engraving are accomplished, and the final product must be thoroughly cleaned of any debris.

What are the differences between General Part and Presentation Part Cutting for Polycarbonate?

Laser cutting of presentation parts requires neat-looking edges. It is not so essential for general components. Laser cutting presentation components from PC is not recommended since it results in slightly discolored edges. However, the results ate going to be of high quality when producing generic components. Laser engraving of polycarbonate is a different thing. The laser beam produces sharp, black marks that are permanent. Thus, engraving presentation parts with a laser is a great option. The same holds for general parts, of course. The production time is low, and the accuracy of the laser is very high.

What speed is better for Polycarbonate with Presentation Parts?

Lower speed gives better results as a rule of thumb for laser cutting PC presentation parts. Thus the laser speed must be at the lower end of the scale, typically seven mm/s. The speed determines how much of the laser power is absorbed by the material. Of course, the speed ultimately depends on the laser power and the sheet’s thickness. Whether a CO2 or fiber laser cutter is used to meet the performance requirements does not matter. It is because the required wavelength is nearly the same in both cases.

What power is better for Polycarbonate with General Parts?

The best power of laser cutting Lexan general parts is relatively low. About 20 W of laser power is enough for sheets of a few mm. For thicker sheets, this value is able to go up by a few Watts. The best strategy is to make a trial run with the PC part, similar to the one that must be laser-cut. This ensures a good quality laser cutting result.

How does Polycarbonate Sheet Thickness affect the laser cutter wattage needed?

PC is cut with a laser because the material absorbs the laser power. The laser beam melts or evaporates the PC. Thus, the thicker the plate is, the more laser power is needed. Thicker sheets are going to demand longer cutting periods since the laser cutting PC power must not be much more than 20 Watts. The aesthetics of the workpiece must not be compromised if the parameters are selected appropriately.

What is the best setting for Laser Cutting Polycarbonate?

The best results for laser-cut polycarbonate will be achieved with low laser power and slow cutting speed. About 20 W and a speed of 7 to 11 mm/s are enough for plates up to several mm thick. The PC is unable to have enough time to melt properly if the speed is considerably more significant, and the plate is not able to be cut entirely through. The PC is going to emit a significant quantity of thick vapors if the power is much greater. Furthermore, the cutting edges are able to get severely burnt.

What are the common mistakes for Laser Cutting Polycarbonate?

Listed below are the common mistakes for Laser Cutting Polycarbonate.

Ignoring Safety Precautions: It is crucial to follow safety procedures at all times while laser cutting polycarbonate. For example, one must wear the proper eye protection and make sure the work environment is sufficiently ventilated. Failing to do so is able to result in significant harm or equipment damage.
Incorrect Material Selection: Selecting the incorrect polycarbonate or a material unsuitable for laser cutting is able to result in unsatisfactory outcomes. It is essential to check with the material supplier or a laser cutting professional to verify that the proper material is utilized.
Poor Edge Quality: Polycarbonate is able to have poor edge quality if the laser is not focused correctly or if the material is not kept firmly in place while being cut. Charring, uneven cutting, or jagged edges are able to result from this.
Melting: Polycarbonate is able to melt during laser cutting, mainly if the laser intensity is too high. It is able to lead to a rough edge finish that needs further finishing work to reach the desired outcome.
Overheating: Polycarbonate is able to quickly overheat during laser cutting, causing bending, cracking, or discoloration. Use the proper laser settings and steer clear of staring at one point for an extended period to prevent this.

What are the beginner tips for Laser Engraving Polycarbonate Sheets?

Listed below are the beginner tips for laser engraving polycarbonate sheets.

Clean up the material: The material must be cleaned after engraving to get rid of any leftover dirt or ink. Clean the surface with a gentle cloth, mild soap, and water, then completely dry it.
Monitor the process: Make sure the engraving process is going well by carefully checking it. Stop the procedure if any problems appear, fix them, and then resume.
Secure the material: Polycarbonate sheets must be firmly kept in place during engraving to avoid movement or shifting. Clamps or other fittings are able to be used for this.
Focus the laser: Achieving precise and accurate results requires a laser that is properly focused. Ensure sure the laser is focused correctly before beginning the engraving process.
Select the correct design: Keep in mind that polycarbonate is a translucent material when picking an engraving design. It implies that both sides of the sheet will display the etched pattern. Using a design that is transparent-friendly or appealing from all angles is something to think about.
Test the settings: It is crucial to test the laser settings on a tiny section of the material before engraving the final design to ensure accuracy. It assists in avoiding any errors or material damage.
Prepare the materials: A clean, debris-free polycarbonate sheet is a must before engraving. Therefore, prepare the material accordingly. Clean the surface with mild soap and water, then completely dry it.
Select the right laser: It is essential when engraving polycarbonate sheets since not all lasers are suited for the material. The best option for engraving polycarbonate is often a CO2 laser since it is able to provide accurate and detailed results without distorting or melting the material.

What is the advantage of laser cutting polycarbonate?

The advantages of laser-cutting PC are precision, low cost, and high speed. The laser cutter’s cutting process is going to be fast and painless if the input files are carefully selected. The accuracy of a laser cutter is much better than one mm. The cutting lines are very thin and precise. The laser is very versatile and is able to cut complicated shapes, such as ornaments, in no time.

What is the disadvantage of laser cutting polycarbonate?

The main disadvantage is that a laser cutter tends to discolor the cutting edges on the PC. Thus, a PC is not the right choice for making presentation parts. Another point is that polycarbonate gives off fumes when it is laser-cut. Those fumes are sometimes quite thick and are able to coat the laser-focusing lens. If this happens, the lens is able to get useless. Applying enough airflow to keep the smoke at bay is able to help prevent this.

Which Laser Cutter is best for Polycarbonate?

The best way to cut polycarbonate is to use a CO₂ laser with a 10.6 µm wavelength. Suitable systems are, for example, the LS series from Boss Laser. This series’s best laser cutter types are the LS-1416 and the LS-1630, respectively. One is able to use the HP series from Boss Laser for larger sheets or industrial-sized batches. CO₂ lasers are best suited because cork absorbs the infrared wavelengths from these lasers very efficiently. Hence, the cutting process is very fast and accurate. Other possible laser cutters are fiber lasers with 10.6 µm wavelength. A UV laser with a 355 nm wavelength is able to be used for engraving.

What are the Polycarbonate Projects for Laser Cutting?

Here are some awesome PC laser-cutting projects from Youtube:

Laser engraving of PC inserts: https://www.youtube.com/watch?v=BzeL30xXSNc
Laser engraving of PC signs: https://www.youtube.com/watch?v=mHk9XuhX1tg
Laser cutting of a decorative PC plate: https://www.youtube.com/watch?v=VkuUGSbUcTA
Laser cutting high-precision parts: https://www.youtube.com/watch?v=FAr3-nxBdOQ
Laser cutting high-precision parts II: https://www.youtube.com/watch?v=nqMk0x8v1Xo
Laser cut PC stencils: https://www.youtube.com/watch?v=8HHvFwR-aVw
Laser cutting PC clothing patterns: https://www.youtube.com/watch?v=t3_oA79Nd2k
Comparing laser engraving PC to other materials: https://www.youtube.com/watch?v=eywQfOA7kic
Making a PC pistol model with a laser cutter: https://www.youtube.com/watch?v=hl3P64PFT04
Laser engraved PC sign with LED illumination: https://www.youtube.com/watch?v=LY8YYVfxogY

What are the alternatives of Polycarbonate for Laser Cutting?

Listed below are the alternatives of Polycarbonate for laser cutting.

Acrylic: Acrylic is a well-liked substitute for polycarbonate since it has a comparable look and is simple to laser cut. It has a shiny, smooth surface and is available in a range of hues and thicknesses. The laser beam eliminates the top layer of the material, while laser engraving acrylic leaves a permanently engraved pattern behind. Acrylic engraving is able with various designs, including text, logos, and images, making it an adaptable material for various uses.
Paper: It is able to be laser-cut to produce complex patterns and designs. It is a flexible substance that is able to be used for a wide range of tasks, such as packaging, invitations, and arts and crafts. Paper engraving burns or etches a thin layer. Paper is a common material for invitations, artwork, and other ornamental purposes because it is able to be engraved with a wide range of designs, including text, pictures, and patterns.
ABS: Acrylonitrile Butadiene Styrene (ABS) is a thermoplastic substance renowned for its sturdiness and endurance. It is often used in home appliances and automobile components and is able to be laser cut. ABS engraving is able to create precise and intricate designs, making ABS a popular material for automotive components, home appliances, and other industrial applications. The laser beam eliminates a fine layer of material from the ABS’s surface, leaving behind a permanent engraved design.
Wood: It is a natural material suitable for precise laser cutting. It is able to be used to make elaborate designs and patterns and is available in a range of thicknesses and varieties. The laser beam eliminates a thin material layer in wood engraving to create a scorched or incised effect. Text, illustrations, and images are able to be engraved into the wood, which makes it a popular material for artwork, signage, and other decorative applications.
PETG: Polyethylene Terephthalate Glycol, sometimes known as PETG, is a form of plastic that resembles polycarbonate in appearance. It is a transparent, thin material that is able to be laser cut and is often used in displays and signs. PETG engraving is able to create intricate designs. Text, images, and other designs are able to be engraved on PETG, frequently used for signage and displays. The laser beam eliminates a fine layer of material from the PETG’s surface, leaving behind a permanent engraved design.

What is the difference between Polycarbonate and Acrylic in Laser Cutting?

Polycarbonate and acrylic are popular laser-cutting materials, but they have significant differences.

Polycarbonate is a strong and impact-resistant material capable of withstanding high levels of tension and pressure without splitting or fracturing. However, it is more heat-sensitive than acrylic, which is able to make laser cutting more difficult. Polycarbonate is susceptible to dissolving or deformation during laser cutting, which reduces the cut’s quality and necessitates more precise laser control settings. It is essential to note that laser-cut polycarbonate emits toxic vapors, necessitating adequate ventilation and safety precautions.

Contrarily, acrylic is a flexible and simple-to-cut material that, when laser cut, creates a clean, polished edge finish. It is less sensitive to heat than polycarbonate, so it is able to be cut at faster velocities without distorting or charring. Acrylic is able to be engraved with a laser to create intricate designs and patterns, making it a popular material for signage, displays, and decorative items, among other uses.

Moreover, cast acrylic is made by pouring liquid acrylic into a mold and cooling it into a sheet. Cast acrylic cutting is popular because it is able to be sliced precisely and offers a clean, smooth edge finish. This material is less heat-sensitive than extruded acrylic and is able to be cut faster without warping or charring.

Laser-cutting cast acrylic requires proper laser settings. Adjusting laser power, speed, and focus are able to guarantee a clean, accurate cut without damaging the material or equipment. Thick-cast acrylic sheets need varied laser settings or numerous passes to cut cleanly.