Laser Cutting
Precision cutting and engraving - Training & Resource Guide
Introduction
▼What is Laser Cutting?
Laser cutting uses a focused laser beam to cut and engrave materials with high precision. The computer-controlled system follows digital designs to create accurate cuts through various materials including wood, acrylic, paper, fabric, and thin metals.
How it Works:
A laser beam is directed through optics and focused through a lens onto the material surface. The laser energy vaporizes or melts the material along the cutting path, while an assist gas blows away the molten material to create a clean cut.
Applications:
- Prototyping and product development
- Architectural models and scale mockups
- Jewelry and fashion accessories
- Signage and decorative elements
- Packaging and templates
- Educational projects and experiments
Material Compatibility
Best results with wood, acrylic, paper, cardboard, fabric, and leather. Some materials like PVC and certain plastics should not be laser cut due to toxic fumes.
Design Resources
▼Nesting & Optimization Tools
Essential tools to optimize material usage by efficiently arranging your designs on sheets - save material and reduce waste.
SVGnest
Browser-based nesting tool that automatically arranges your designs to minimize waste. Upload SVG files and optimize material usage instantly.
- Automatic layout optimization
- Browser-based, no installation
- SVG file support
- Real-time nesting preview
Deepnest
Advanced open-source nesting software with powerful algorithms to pack shapes efficiently. Desktop application for serious nesting needs.
- Advanced nesting algorithms
- Open-source software
- Multiple file format support
- Material cost calculation
LightBurn Nesting
Professional nesting built into LightBurn software. Automatic and manual nesting options with advanced optimization.
- Integrated with LightBurn
- Automatic & manual modes
- Advanced optimization
- Professional results
Essential Web-Based Generators
Browser-based tools requiring no installation - perfect for immediate student use and creative exploration.
Cuttle
Premier browser-based parametric design tool built specifically for laser cutting. Create jewelry, ornaments, and personalized items through drag-and-drop interfaces.
- Real-time parameter adjustments
- Drag-and-drop interface
- Free access with premium features
- Perfect for beginners
Pattern Monster
Instant access to over 248 customizable patterns with adjustable scale, rotation, and colors. Commercial-use license included.
- 248+ customizable patterns
- Seamless SVG export
- Commercial-use license
- No design experience required
Boxes.py (Festi's Boxes)
Comprehensive platform offering 80+ different mechanical components, boxes with finger joints, gears, and structural elements.
- 80+ component types
- Automatic kerf compensation
- Parametric box generation
- Engineering & artistic applications
MakerCase
Simple and intuitive box generator perfect for beginners. Create custom boxes with various joint types in minutes.
- Beginner-friendly interface
- Multiple joint options
- Instant SVG download
- Quick prototyping
Make a Box
Simple parametric box generator with finger joints - perfect for quick container designs.
- Quick box generation
- Finger joint options
- Beginner-friendly
- Instant SVG download
FFFUEL
Multiple generators for mesh gradients, isometric patterns, and oscillation curves. Perfect for unique backgrounds and artistic elements.
- Mesh gradient generator
- Isometric pattern tools
- Oscillation curves
- Artistic backgrounds
PatternPad
Create unlimited unique pattern designs. Beautiful online pattern editor for creating seamless patterns.
- Seamless pattern creation
- Visual editor interface
- SVG export
- Unlimited designs
Voronoi Editor
Create beautiful Voronoi diagrams and patterns. Perfect for organic, cell-like decorative designs.
- Voronoi diagram generation
- Interactive editing
- Organic patterns
- SVG export
Template Maker
Creative Commons collection of paper boxes and fold patterns with assembly guides. Perfect for packaging design.
- Paper box templates
- Fold pattern library
- Assembly instructions
- Creative Commons license
DrawingBots.net Tools
Collection of creative algorithms and tools for generating plotter-friendly and laser-cut designs.
- Generative art tools
- Plotter-friendly output
- Multiple algorithms
- Creative exploration
Jerome Leary's Gears
Precise gear generator for functional mechanical projects and kinetic art installations.
- Precision gear generation
- Multiple gear types
- Mechanical accuracy
- SVG export
Maze Generator
Generate custom mazes in various shapes and sizes. Perfect for puzzles and decorative projects.
- Multiple maze algorithms
- Custom dimensions
- Various maze styles
- Printable output
LaserCutMazes
Specialized maze generator optimized for laser cutting with customizable walls and paths.
- Laser-cut optimized
- Customizable wall thickness
- 3D maze options
- SVG export
Jigsaw Puzzle Generator
Generate custom jigsaw puzzle patterns for laser cutting your own puzzles.
- Custom puzzle patterns
- Variable piece counts
- Laser-cut ready
- SVG output
Blocklayer Templates
Extensive collection of practical templates including tube mitre patterns, protractors, and construction aids.
- Tube mitre patterns
- Protractor templates
- Construction aids
- Engineering tools
Specialized Tools for Artistic Disciplines
Tools optimized for specific creative applications - typography, mechanical art, and specialty design.
Stencilfy
Converts any font to laser-cutter-friendly stencil format. Perfect for signage and decorative text.
- Font-to-stencil conversion
- Laser-ready output
- Any font supported
- Instant generation
Advanced Software Progression
For students ready to advance beyond web-based tools - comprehensive open-source and professional alternatives.
Inkscape
Industry-standard vector graphics editor with laser cutting extensions. Complete ecosystem for creative work.
- Professional vector editing
- Laser cutting extensions
- Cross-platform support
- Extensive tutorials
LightBurn
Professional laser cutting software with advanced features for design, layout, and machine control.
- Professional laser control
- Advanced design tools
- Material library
- Job optimization
LibreCAD
Precision drafting for technical laser cutting projects. Free open-source CAD software.
- Precision 2D drafting
- Technical drawing tools
- Layer management
- Professional output
OpenSCAD
Programming-based parametric design for students interested in code-driven creative workflows.
- Code-based parametric design
- Precise mathematical control
- Systematic design thinking
- Educational value
FreeCAD v1.0
Professional-grade parametric modeling with Python scripting and comprehensive 2D/3D integration.
- Professional parametric modeling
- Python scripting capabilities
- 2D/3D integration
- Workbench specialization
Blender (Laser Cutting Addons)
Most advanced capabilities with Flatterer, Laser Slicer, and ShapeMuse addons for 3D-to-2D workflows.
- Flatterer (3D mesh to SVG)
- Laser Slicer (3D slicing)
- ShapeMuse (procedural patterns)
- Complex 3D-to-2D workflows
Free Template Libraries & Community Resources
Extensive learning-by-example opportunities and practical project starting points.
3axis.co
Collection of 17,353+ free laser cut templates for learning and inspiration.
- 17,353+ free templates
- Learning by example
- Project inspiration
- Immediate download
Vecty.co
Multi-format downloads with extensive vector library for laser cutting projects.
- Multi-format support
- Extensive vector library
- Project templates
- Free downloads
Cults3D (Laser Files)
Independent marketplace with laser cutting files (DXF, SVG). Free and paid designs from community creators.
- DXF & SVG files
- Free & paid options
- Designer-focused platform
- Community marketplace
Material Safety Guide
▼This guide helps you explore the wide range of materials you can use with a laser cutter, set realistic expectations for new materials, and stay safe while doing so.
Before Using a New Material
- Check the Material Safety Data Sheet (MSDS) — it lists harmful gases or byproducts from burning/melting the material
- If the material can release flammable, toxic, or corrosive gases, find an alternative method (e.g. CNC)
- If anyone near the laser feels unwell, stop immediately, ventilate the space, and verify the material is safe
- Never leave the laser cutter running unattended
- Keep a fire extinguisher and fire blanket close — some materials catch fire quickly
- Hard materials (ceramics, stones): dry completely before use — absorbed water causes steam explosions and flying fragments
Materials to Never Laser Cut
- PVC (Polyvinyl Chloride): releases toxic, corrosive gases including hydrochloric acid — damages lungs and the machine's optics
- Neoprene / synthetic rubber containing chlorine: releases toxic gases. If you can't identify the rubber type, do not cut it
- PTFE / Teflon: releases dangerous fumes; requires a specifically designed ventilation system
- Chromium VI leather (some tanned leathers): releases toxic chromium compounds. Test with a chromium spot kit if unsure
- Carbon fibre: releases harmful particles and gases
- PVB (Polyvinyl Butyrale): similar hazards to PVC
- Beryllium Oxide: releases toxic dust when processed
- Styrofoam / polystyrene foam: extremely flammable; releases styrene gas in large quantities — NEVER use in the laser cutter
- Materials with epoxy or phenolic resins: emit toxic gases
- ABS, nylon, polyurethane, some acrylics (CN-bond materials): can produce hydrogen cyanide (HCN) gas — requires chemical filters and strong ventilation
- Fiberglass composites: releases styrene, benzene, and HCN; also produces uneven cuts due to material inhomogeneity
- Polycarbonate >1mm thick: absorbs infrared strongly, overheats, significant fire hazard; edges discolour badly
- Unidentified plastics: if you cannot identify the plastic, do not cut it
Safe Materials Reference
| Material | Cut | Engrave | Notes |
|---|---|---|---|
| Cardboard | ✓ Yes | ✓ Yes | High speed, medium power. Good ventilation essential. Thicker cardboard loses focus deeper in. |
| Cork | ✓ Yes | ✓ Yes | Low smoke. Adjust power for shading range — light brown to deep black engravings. |
| Natural wood (balsa, pine, oak, etc.) | ✓ Yes | ✓ Yes | Softer woods need less power. High-resin woods (cherry, alder) give richer engravings but catch fire more easily. Watch for knots. |
| Plywood | ✓ Yes | ✓ Yes | Adhesives release formaldehyde — good ventilation required. Tougher to cut cleanly than natural wood. |
| MDF | ✓ Yes | ✓ Yes | More consistent than plywood; formaldehyde from adhesives — ventilation required. |
| Natural fabrics (cotton, linen, silk, felt, denim, fleece, twill, microfibre, polyester) | ✓ Yes | ✓ Yes | High speed, low power for engraving. Some edge singeing is normal. |
| Natural leather | ✓ Yes | ✓ Yes | Distinct smell but not toxic (natural leather only). Thick leather may need multiple passes. Test for chromium VI before cutting. |
| Nylon, spandex | ✗ Avoid | ✗ Avoid | Synthetic fibres — hazardous when cut. See hazardous materials section. |
| Acrylic / PMMA (cast) | ✓ Yes | ✓ Yes | Cast acrylic → frosted engraving. Fire hazard — never leave unattended. Up to ~12mm depending on laser power. |
| Acrylic / PMMA (extruded) | ✓ Yes | ⚠ Less ideal | Extruded acrylic cuts with polished edges. Less contrast when engraved. |
| Polypropylene (sheets, not foam) | ⚠ Caution | ⚠ Less ideal | Low melting point; thin pieces may warp. PP foam is a significant fire hazard — avoid. |
| Coroplast (corrugated PP) | ⚠ Caution | ⚠ Difficult | Large surface area increases fire risk. Fluted sections require more power than face sheets. |
| Delrin / Acetal | ⚠ Caution | ⚠ Caution | Clean cuts, low contrast engravings. Releases formaldehyde — strong ventilation required. Thin samples may warp. |
| Polyimide / Kapton | ⚠ CO2 limited | ✓ Engrave only | CO2 laser burns and chars when cutting. Engraving gives black soot marks with good contrast. UV laser cuts cleanly. |
| Natural rubber / silicone | ✓ Yes | ✓ Yes | Natural rubber and silicone are fine. Produces smoke and residue — ventilation required. Neoprene and chlorine-containing rubbers are hazardous — do not cut if unsure of type. |
| Polycarbonate (thin, <1mm) | ⚠ Thin only | ⚠ Poor results | Only thin sheets. Absorbs IR strongly → overheats. Fire hazard. Edge discolouration is common. |
| Anodized aluminium | ✗ No cutting | ↑ Engrave only | CO2 laser etches the oxide layer cleanly. No smoke/residue but abrasive Al₂O₃ particles — clean machine thoroughly after use. |
| Bare metals (CO2 laser) | ✗ Not recommended | ⚠ Limited | Highly reflective. CO2 laser lacks intensity for bare metal cutting. Cermark™ compound applied to surface enables marking. Laser annealing possible on colour-changing alloys. |
| Glass | ✗ Very limited | ↑ Engrave only | Creates frosted appearance from microfractures. Fine detail engraving is difficult to control. Thin glass (<1mm) can be cut with careful thermal control. |
| Ceramic tile | ✗ No | ⚠ Limited | High sintering temperature; generally not feasible. Can be marked if coated with glaze or paint. Porous ceramics must be completely dry before use — moisture causes steam explosions. |
| Stone (marble, granite, slate) | ✗ No | ↑ Engrave only | Dark polished stones engrave well with good contrast. Deep engraving not feasible. Must be completely dry — moisture causes surface fragmentation. |
Sources: materialseducation.org · ATX Hackerspace · Dallas Makerspace · Material Safety Data Sheets
File Formats & Stencil Fonts
▼File Formats for Laser Cutting
| Format | Type | Use |
|---|---|---|
| SVG | Vector | Best for cutting — scalable, no quality loss |
| DXF | Vector/CAD | Standard for CAD-originated designs |
| AI | Vector | Adobe Illustrator files |
| Vector/Mixed | Accepted by most laser software | |
| HPGL / PLT | Vector/Plotter | Older plotter format, still supported |
| PNG / JPEG / BMP / TIFF | Raster | Engraving/rastering only — not for cutting paths |
Cutting Text: Use Stencil Fonts
When cutting text with a laser, standard fonts will cause the centres of letters like O, A, B, D, P, Q, R to fall out. Use stencil fonts — fonts with bridges connecting enclosed areas to the outer letterform. Here are tested free stencil fonts:
Alternatively, use Stencilfy to automatically convert any existing font into a laser-cutter-friendly stencil format.
Additional Resources & Learning
▼LaserUser.com
The most comprehensive free educational resource for laser cutting — 400+ professional videos covering software workflows, material selection, safety protocols, and troubleshooting.
Visit LaserUser.comInvolute Spur Gear Builder
Precise involute gear profiles for functional mechanical art installations. Generates SVG files ready for laser cutting.
Generate GearsEvolvent Design
Professional gear generator with accurate involute profiles. For working kinetic art and mechanical projects.
Design GearsKrita
Free, open-source painting and vector software — good for students working across raster and vector workflows before exporting to Inkscape.
Download KritaDiscord — LaserCord Community
Active laser cutting community with real-time support, project sharing, and troubleshooting. Great for getting immediate feedback on your work.
Join LaserCordSVGnest
Automatically arranges your design parts to minimise material waste — essential for efficient use of sheet material. Upload SVG files, optimise layout, download.
Try SVGnestFrequently Asked Questions
▼What materials can be laser cut?
Wood, acrylic, paper, cardboard, natural fabrics, leather, cork, and certain plastics (see the Material Safety Guide above). Avoid PVC, neoprene, carbon fibre, Styrofoam, ABS, and any material you cannot identify.
What file formats are needed?
Vector formats — SVG, DXF, or AI — are required for cutting. Raster images (PNG, JPG) can be used for engraving only. Paths must be closed and stroked (not filled) for cutting operations.
How thick can materials be?
Typically up to ~12mm for acrylic and 6–9mm for wood, though this depends on your laser's wattage. Thicker materials may need multiple passes or may not cut cleanly. Check with Maker Station staff for your specific project.
Why can't I cut text with standard fonts?
Letters with enclosed areas (O, A, B, D, P, Q, R) will lose their interior pieces when cut. Use stencil fonts (see the File Formats section above) or use Stencilfy to convert any font automatically.
The laser cutter is not firing — what do I do?
Check the lid is fully closed (safety interlock), verify the machine is powered on and not in a paused state, check the laser power setting in LightBurn is above 0%, and ensure the file has been sent correctly. Contact Maker Station staff if the issue persists.
Do I need special software?
For design: Inkscape (free) or Adobe Illustrator. For machine control: LightBurn (installed on the Maker Station computer). Many designs can be started with the free web-based tools in the Design Resources section above.
How do I prepare files for cutting?
Ensure all cut paths are vector lines (not filled shapes), paths are closed, and your document is scaled to real-world dimensions. Add kerf compensation (~0.1–0.2mm offset) for precise fit. Remove any raster elements that aren't needed for engraving.