Laser Engraving Production File Setup

Vector vs Raster Layer Separation: Assign cut paths to one layer, engravings to another for automatic job routing.

Kerf Offset Calculation: Shrink or expand cut paths to compensate for laser beam width.

Material Library: Load power/speed/frequency presets for wood, acrylic, leather, metal, and more.

1. Format: Vector paths (SVG, PDF, AI, DXF) for cutting, raster images (PNG, JPG) for engraving.
2. Cut Path: Hairline stroke (0.001" or "Hairline" in software) on a dedicated layer (typically red or "CutContour").
3. Engrave Layer: Black fill for raster engraving, or vector fill for vector engraving (slower but more consistent).
4. Kerf Offset: Beam width compensation for press-fit parts (typically 0.1-0.2mm per side).

Vector Cutting: Laser follows path outline, cuts through material. Used for shapes, parts, stencils. Fast, precise edges.

Raster Engraving: Laser scans back and forth like a printer, removing surface material. Used for photos, text, textures. Slower, variable depth.

Vector Engraving: Laser follows path outline but doesn't cut through. Used for line art, borders, hatching. Faster than raster for simple shapes.

Every material requires specific settings. Too much power = charring; too little = incomplete cuts.

Power (%): Laser wattage output. Higher power cuts thicker materials or engraves deeper.

Speed (mm/s or in/s): How fast laser head moves. Slower = more energy per area = deeper cut/engrave.

Frequency (Hz or PPI): Pulse rate. Higher frequency = smoother edges on wood, lower = deeper engraving on acrylic.

### Common Material Settings (40W CO2 Laser)

3mm Plywood: Cut at 20mm/s, 80% power, 500Hz. Engrave at 300mm/s, 30% power, 1000Hz.

3mm Acrylic: Cut at 10mm/s, 70% power, 5000Hz. Engrave at 400mm/s, 40% power, 5000Hz.

3mm MDF: Cut at 15mm/s, 90% power, 500Hz. Engrave at 250mm/s, 25% power, 1000Hz.

Leather (2mm): Cut at 40mm/s, 50% power, 1000Hz. Engrave at 500mm/s, 20% power, 1000Hz.

Cardboard (corrugated): Cut at 60mm/s, 40% power, 500Hz.

Higher-wattage lasers (60W, 100W, 150W) use proportionally lower power percentages for the same material.

Kerf is the width of material removed by the laser beam (typically 0.1-0.3mm). For press-fit parts (box joints, puzzle pieces, inlays), compensate kerf to achieve tight tolerance

Male Parts (tabs): Shrink outline by half the kerf (e.g., 0.1mm offset inward).

Female Parts (slots): Expand outline by half the kerf (e.g., 0.1mm offset outward).

Inlays: Expand the inlay pocket by full kerf (0.2mm) so the insert drops in snugly.

Test kerf on scrap material first — every laser and material combination has slightly different kerf width.

Focus Height: Distance from lens to material surface. Incorrect focus = wide kerf, poor edge quality, incomplete cuts. Focal point should sit at material top surface for cutting, mid-thickness for engraving.

Air Assist: Compressed air blown at cut point to remove smoke and prevent charring. Essential for clean cuts on wood and acrylic. Turn off for paper (air blows it around).

Separate cut paths and engraving areas by layer or color

Red (or CutContour layer): Vector cuts, highest power, slowest speed. Runs last to prevent parts from shifting.

Black (or Engrave layer): Raster or vector engraving, medium power, fast speed. Runs first.

Blue (or Score layer): Light vector engraving for fold lines, medium power, medium speed.

Laser software reads colors/layers and assigns different power/speed to each.

Thick materials (>6mm wood, >10mm acrylic) require multiple passes

Pass 1: 80% power, 15mm/s.

Pass 2: 90% power, 12mm/s.

Pass 3: 95% power, 10mm/s (if needed).

Lower power on first pass prevents excessive charring. Increase power on later passes to push through remaining material.

Never laser cut: PVC (releases chlorine gas), vinyl (toxic), polycarbonate (melts and releases cyanide), fiberglass (releases glass dust), any material containing chlorine or fluorine.

Safe materials: Wood, plywood, MDF, acrylic (cast, not extruded), leather (vegetable-tanned, not chrome-tanned), paper, cardboard, fabric (cotton, polyester), glass (CO2 etching only), anodized aluminum (fiber laser).

Charred Edges: Power too high, speed too slow, or insufficient air assist. Reduce power 10%, increase speed 20%, verify air compressor pressure.

Incomplete Cuts: Power too low, speed too fast, or focus height incorrect. Increase power or reduce speed, check focus with calibration tool.

Wavy Cut Lines: Laser head loose, belts slack, or lens dirty. Tighten belts, clean lens with isopropyl alcohol and lens paper.

Flame-Polished Edges (acrylic): Correct. Acrylic melts and self-polishes when laser-cut. To prevent, use masking tape on both sides before cutting.