Laser Cutting Materials - Will it melt, burn or shatter? Oh My!
Posted by Doug Cooke on Mon, Nov 08, 2010 @ 10:45 AM
We get a regular flow of inquires from people who have had bad experiences in their quest to have things laser cut. Frequently the requests for information reference product that was yellowed, melted, burned or shattered in the previous attempt at their project. Well first of all lasers cut by melting or vaporizing the material being cut. However when this is done in a very controlled way there should not be a negative impact on the material being cut or etched. When we look at the samples sent to us that failed more often then not what we find is the variables for doing the cutting were set to be too powerful to yield an acceptable result. The other very common problem is that too powerful a laser was used to attempt the project and it just could not be adjusted downward enough to yield a successful execution.
Many materials require very specialized settings to be cut cleanly without unattractive or damaging side effects. We approximate that on any given laser cutting project there are 13 variables that can be adjusted or brought into play that effect the quality of deliverables. Most companies are working with 4 to 6 variables and find themselves very limited with a short list of materials that cut cleanly.
Examples of materials that should cut very cleanly but frequently come to us with issues are Nylon, polypropylene, acrylic, various rubbers used for gaskets, Teflon and wood. On the other hand in the difficult to laser cut or etch category are materials like Kapton, polycarbonate, G-10 and silicon wafers. Of course there are very workable settings for these materials but patience, experience and a lot of knowledge go a long way on the road to success.
A good example is polycarbonate which is always difficult to cut, but when done correctly the edge should not be too yellow or too rough. Material thickness is a major factor influencing success with this material as well. Of course a cut that is cosmetically acceptable to one person may not be to another so it is important to keep in mind that industrial materials often yield industrial results as part of their “tough material” nature. If you are unsure what to expect from the material or supplier you’re considering, ask to have a sample cut or sent for review. In most cases this will give you the information needed for your next steps or questions.