A CO2 laser is a machining technology in which a focused infrared beam (wavelength 10.6 μm) melts, burns or vaporises material along a programmed path. CO2 radiation is particularly well absorbed by organic materials — acrylic, wood, leather, fabric — which is why this laser type dominates the processing of plastics and decorative materials. See the laser and CNC services in our offer.
How Does a CO2 Laser Work?
A laser tube filled with a CO2, N₂ and He mixture generates an infrared beam at 40–150 W (typical for production workshops). The beam is directed by a mirror system and focused through a lens onto the material surface to a spot of 0.1–0.3 mm diameter. At that point the power density is so high that the material is instantly vaporised or melted.
The head moves along XY axes at up to 1000 mm/s. Power and speed settings control:
- cut depth (full cut-through vs surface engraving)
- edge quality (smooth, clear vs slightly charred)
- kerf width — typically 0.1–0.3 mm
Materials Suitable for CO2 Laser Cutting and Engraving
✅ Excellent materials for CO2 laser
Acrylic (PMMA) The CO2 laser is virtually made for acrylic. The cut edge is flame-polished by the beam — smooth, transparent, almost like mechanically ground. Engraving creates a milky-white, backlit trace on a clear sheet. Cuttable thicknesses: 2–20 mm (up to 25 mm at higher power).
Plywood and timber Laser cuts precise contours, creates filigree patterns and engraves the natural wood grain. The edge is brown (charred) — the characteristic laser-on-wood effect. Hardwoods (birch, oak) require lower speed than softwoods (poplar).
MDF and HDF Uniform structure with no knots — ideal for precise patterns. Important: MDF contains urea-formaldehyde resins that require an effective extraction and filtration system during laser cutting.
Natural and vegan leather The laser cuts leather with a clean edge and simultaneously seals it. Engraving creates a permanent raised pattern. Applications: straps, labels, personalised accessories.
Felt and technical fabrics Laser cutting produces no fraying — unlike scissors or blades. Ideal for decorative elements, felt gaskets and fabric patterns.
Rubber and cork Precision-cut gaskets, anti-slip pads, cork stamps.
Paper, board and cardboard Intricate paper filigrees, invitations, packaging, stencils.
Acrylic resins and photopolymers Stamp engraving, casting moulds.
⚠️ Materials with limitations
Polycarbonate (PC) — CO2 laser does not cut PC cleanly. The edge burns, yellows and becomes brittle. We use CNC milling for polycarbonate — details in our multiwall polycarbonate article.
EVA and PE foams — can be cut, but the edge melts rather than vaporises. Result depends on foam density.
Metals — CO2 laser at 10.6 μm does not cut metals (aluminium, steel). A fibre laser or plasma is needed. Exception: engraving anodised aluminium and marking stainless steel by vaporising a coating.
❌ Materials NEVER to cut with a laser
PVC and vinyl — cutting PVC with a laser releases hydrogen chloride (HCl) — a toxic gas that destroys the laser optics and is dangerous to health. This is an absolute prohibition at every laser workshop.
Chlorine-, bromine- or fluorine-containing materials — chlorinated rubber, some composites.
Polyurethane foams with isocyanates — dangerous fumes.
If you are unsure of your material's composition — ask us before delivery.
Laser Machining Parameters
Three main parameters control the process:
Power — 10–100%
Adjusts beam energy. Higher power = deeper cut. Engraving typically runs at 20–60% power.
Speed — mm/s
Higher speed = less energy per mm of material = shallower mark. Lower speed = more energy = deeper/cleaner cut, but risk of overheating.
Pulse frequency (Hz)
Affects cut continuity and edge smoothness. Higher frequency = more continuous line (smoothing effect). Particularly important for acrylic.
Example parameters for common materials (80 W laser)
| Material | Thickness | Power | Speed | Passes |
|---|---|---|---|---|
| Acrylic | 3 mm | 65% | 15 mm/s | 1 |
| Acrylic | 8 mm | 85% | 8 mm/s | 1 |
| Birch plywood | 4 mm | 75% | 12 mm/s | 1 |
| Birch plywood | 8 mm | 90% | 6 mm/s | 2 |
| MDF | 3 mm | 70% | 14 mm/s | 1 |
| Leather | 3 mm | 55% | 20 mm/s | 1 |
| Engraving — acrylic | — | 25% | 300 mm/s | 1 |
| Engraving — plywood | — | 40% | 250 mm/s | 1 |
Indicative values — adjusted individually for each machine and material grade.
CO2 Laser vs CNC Milling — Which to Choose?
Both technologies are complementary, not competing. The choice depends on the project:
| Criterion | CO2 Laser | CNC Milling |
|---|---|---|
| Minimum cut width | ~0.1–0.2 mm (kerf) | ~2–3 mm (cutter diameter) |
| Raster engraving (photos, fills) | ✓ excellent | ✗ very slow |
| Thick materials (>20 mm) | ✗ limited power | ✓ no problem |
| Polycarbonate | ✗ poor edge quality | ✓ good edge |
| Metals | ✗ (CO2) | ✓ aluminium, brass |
| Acrylic edge | ✓ polished, clear | ✓ matte (needs polishing) |
| Forces on material | none (no clamping needed) | ✓ clamping required |
| 3D relief (pocket milling) | ✗ 2D only | ✓ |
| Speed on thin sheets | ✓ faster | — |
Practical rule: thin materials with fine contours → laser. Thicker materials, polycarbonate, 3D profiles → CNC milling.
Edge Quality and Engraving Effects
Laser-cut acrylic edge
The CO2 laser edge on acrylic is optically polished — transparent, smooth, with no tool marks. If the part is edge-lit (light guide), the laser creates a light effect without further processing.
Wood and MDF edge
Dark brown, slightly charred. The characteristic "burnt wood" smell fades after a few hours. In veneered plywood the edge may reveal layer lines — a natural effect.
Raster engraving
The laser can "raster scan" — sweeping row by row like a printer — to engrave photos, gradient fills, relief patterns on wood. Resolution up to 500–1000 DPI depending on material.
Vector (contour) engraving
Following a vector path at reduced power. Fine lines, text, logos — on acrylic they produce a milky-transparent effect.
Applications
Advertising and signage
- Letters and logotypes from acrylic — laser-cut contours, polished edges
- Plaques and signs — engraving on acrylic, plywood, laser laminate
- Trophies and medals — photo and text engraving on wood and acrylic
- LED edge-lit panels — acrylic with vector engraving visible in edge lighting
Craft and personalisation
- Wedding and event invitations — paper, cardboard, wood
- Wooden boxes and packaging — filigree patterns, engraved lids
- Pendants and jewellery — acrylic, leather, wood
- Leather and fabric patterns — personalised accessories
Industry and prototyping
- Templates and painting masks — precision cuts from film or cardboard
- Gaskets and washers — rubber, cork, felt
- Architectural models — plywood and acrylic to scale
- Electronics — acrylic front panels, engraved button legends
Education and institutions
- Information boards, directional signs
- Educational aids — cross-section models, educational puzzles
Extraction and Safety
Every laser cut produces fumes and vapours. Our workshop is equipped with:
- Inline extraction — directly at the cutting head
- Active-carbon and HEPA filtration — cleans air from organic combustion products
- Chlorine-presence sensors — protection against accidental PVC cutting
Customer materials are verified before processing. If the composition is uncertain — please provide a safety data sheet (SDS) or a sample for testing.
Have a laser cutting or engraving project? Ask for a laser and CNC service quote — workshop in Szczecin with CO2 laser and CNC mills. Also see the full materials offer and CNC services.