How To Laser Cut Plastic?

I put a piece of plastic into the laser cutter and pressed the start button. The results can vary greatly: Either you get a perfect part with clean edges and exact dimensions. Or you get a sudden burst of choking yellow-green smoke from the machine, and a pungent smell that hits your face. This is not just as simple as dirtying the precious focusing lens in the machine. Worse,you may accidentally release toxic gases.

This is the reality oflaser cut plastic: Choose the right material, get twice the result with half the effort. Choose the wrong one, at best, the material will be scrapped and the equipment will be damaged, or at worst, it will endanger safety.

There are so many types of plastics, with very different compositions, and their reactions to lasers vary greatly. Some plastics are just not suitable or even impossible to cut, but there are also many common plastics that are our "good helpers". Mastering this, laser cutting plastic can become a very handy tool in our hands, helping us to quickly and accurately make various parts with fine designs.

Whether it is making samples, making logos, cutting packaging or making complex product parts, it is very useful in our dailymanufacturing process. So, the core of this guide is to help you avoid pitfalls, figure out which plastics can be cut safely and efficiently with a laser, how to cut them, and what safety points must be kept in mind when operating. Let's talk about it in detail.

Summary Of The Core Answers:

Plastic type	Laser cutting suitability	Key reasons/precautions
Acrylic/PMMA	✅ Excellent	Smooth edges like flame polishing for the best effect.
ABS	⚠️ Caution is required	Will melt and produce unpleasant odors, with average edge quality.
Polycarbonate (PC)	🚫 Not recommended	Absorbing infrared laser, prone to discoloration and ignition, with poor effectiveness.
Polyvinyl chloride (PVC)	☠️ Absolutely prohibited	Release highly toxic chlorine gas, corrode machines, and pose a health hazard.
PETG	⚠️ Caution is required	Easy to melt and adhere, requiring precise parameter settings.
Acetal resin (Delrin/POM)	✅ Good	The cutting is clean, but the odor is strong and requires good ventilation.
Polypropylene (PP)	🚫 Not recommended	After cutting, it will turn into a molten viscous substance.

This article will answer your questions:

This guide will show you how different plastics behave under lasers, and highlight which materials should never be touched. Wrong choices may cause equipment damage or safety hazards.
We will use a real-life example (comparison of acrylic prototypes and ABS functional parts) to clearly show how material selection affects the results.
Finally, we will provide practical answers to common operational issues such as cutting thickness and laser selection to help you apply laser cutting technology safely and efficiently.

Why Trust This Guide? JS's Laser And Material Science Practice

Every experience here comes from the actual operation table in our JS company's laser cutting workshop. One of our core businesses is the production of high-precision Laser cutting parts. For example, when a customer wants to cut a transparent and smooth display piece out of 10mm thick acrylic, or when they want to cut a piece of PVC or thick polycarbonate, we will directly tell them"this is really not possible",explain clearly that lasering these materials will release harmful gases, and recommend saferCNC machiningsolutions.

Which plastic is best cut with CO2 laser, how to adjust the parameters, or why fiber laser is not suitable for cutting certain plastics. These knowledge are not copied from books, but are obtained through our machine after machine and repeated processing.

This guide is accumulated by ourJS engineeringteam through countless times of adjusting power, testing speed, checking frequency, and cleaning up the cut and burnt material scraps.

"Arthur Schawlow, one of the pioneers of laser physics, said: To do laser work, you have to learn to talk to light."

It is through day-to-day "dialogue" that we have thoroughly understood the performance of the machine and truly understood the performance and safety margins of different plastics under laser. What we share here is the operating rules that we have actually worked out to ensure safety and reliability."

The Science Of Laser Cutting Plastics: Melting, Vaporization Or Combustion?

Laser cutting plastics is not a simple cut. In essence,we use a beam of high-energy light to accurately "talk" to the material.Understanding how this conversation goes, whether it melts, vaporizes, or unfortunately burns, is definitely the first step to choosing the right material and making goodlaser cutting parts.

CO₂ laser: Why is it so "compatible" with plastics?

In our JS workshop,CO₂ laser is the absolute main force for cutting organic materials such as acrylic.The reason is simple: the infrared light (wavelength 10.6μm) it emits is just liked by the molecular structure of most plastics (such as wood and acrylic), and can be efficiently absorbed. The energy is quickly "eaten" by the material, the temperature instantly soars to the vaporization point, the material directly turns into gas and is blown away by the auxiliary gas, and the incision is naturally clean and neat.

Melting and vaporization: the watershed of incision quality

Ideal situation:

Clean vaporization (such as acrylic/PMMA): Acrylic can absorb 10.6 μm laser, quickly reach the vaporization point, and directly form gas to be blown away. The residual heat on the edge will melt the surface slightly, making it look like it has been flame-polished, translucent and smooth, which is the key to making high-quality display parts forlaser cutting.

Troublesome situation:

Over-melting (such as ABS, PETG): This type of material is easier to melt. Because the melting point of ABS at 300°C and the vaporization point at 350° are too close. When the laser is irradiated, it does not turn into gas quickly,but turns into molten material first.

The result is that the edge of the cut is rough, covered with slag, and even sticks back to itself, which greatly reduces the quality of the parts and makes it difficult to clean up.

Absolutely forbidden area: Chlorine-containing plastics - the "poison" of laser cutting

At JS, if I encounter customers who want to do laser cutting of chlorine-containing plastics such asPVC and vinyl,I will refuse without hesitation.This is not an exaggeration, it is really fatal:

Highly toxic gas: High-temperature lasers will cause them to decompose and release hydrogen chloride (HCl) gas. Inhaling this thing will cause devastating burns to the respiratory tract, and the consequences are extremely serious.
Machine killer: HCl gas will turn into hydrochloric acid immediately when it meets the moisture in the air! This acid mist will corrode all the metal parts in the machine crazily, including the precision rails, screws, and especially the expensive optical lenses, which will be scrapped in minutes. One cutting will destroy a machine,and I am not kidding.

Common plastic laser cutting (CO₂) characteristics and risks:

Plastic type	Absorption rate of CO₂ laser	Main cutting mechanism	Typical manifestations of incision quality	Main risk level
Acrylic (PMMA)	Extremely high	Lead: Gasification	Smooth, transparent, edge melt polished.	Low (requiring ventilation).
ABS	Tall	Lead: Melting	Easy to melt slag, rough edges, and may re solidify.	Medium (with high smoke and possibly trace amounts of benzene derivatives).
PETG	Tall	Lead: Melting	Easy to draw and prone to carbonization at the edges.	Medium (with high levels of smoke and dust).
PVC (chlorine containing)	Tall	Decomposition/Combustion	Severe carbonization and irregular edges.	Extremely high! (Highly toxic HCl gas, highly corrosive).
Polycarbonate (PC) thick plate	Rising-falling	Easy to melt/carbonize	Easy to yellow, crack, and accumulate slag.	Medium to high (with high smoke and possibly containing phenol).

Data from ISO 11553, ECHA risk assessment report

"Understanding whether the material melts, vaporizes or decomposes during laser cutting of plastics is directly related to part quality, operational safety and equipment life. I strongly recommend that you thoroughly understand the laser processing characteristics of any new material before trying it. Safety and quality always come before speed. When you are unsure about the material, feel free to contact our JS team to chat, don't take risks!"

Guide To Laser Cutting Plastic Materials: Traffic Light Rule

I have run laser cutting for more than a decade and worked with manyplastic materials. Today, I am going to utilize the well-known "traffic light" principle, as well as my practical experience, in explaining the key points in cutting common plastics, especially the problems that need to be observed when using our everyday CO₂ laser cutting machine.Safety first, effect second!

✅ Green Light Zone: Cut with Confidence (Suggested Materials)

Acrylic (PMMA):Laser Cutting's "Golden Partner." CO₂ laser absorption rate > 90%, and it can vaporize neatly and cleanly, and the cut edge is as smooth and transparent as glass Ra≤3.2μm, and almost no secondary processing is required. It's the most popular material for signs, display models, and precision parts in our online laser cutting services.

Acetal resin (POM / Delrin):High cutting accuracy and smooth and neat edges are appropriate for wear-resistant parts such as gears, bearings, and functional parts. Note: The odor is strong when machining and the ventilation system has to be fully functional! It needs to be equipped with a ≥500m³/h air volume exhaust system (formaldehyde emission 0.5ppm).

Polyester film (PET Film / Mylar):For thin films (usually <0.5mm), laser can achieve very fine, non-melt edge cutting, which is often utilized to make templates, electronic insulation sheets, etc.

⚠️ Yellow light area: Try with caution

ABS:Can be cut, but the effect is not ideal. It is easy to melt rather than vaporize when cutting, and the edges will be sticky and yellow, while releasing obvious smoke and the smell of trace styrene monomer. Unless it is a rough blank with no requirements on the edges, it is really not recommended. Ventilation must be combined with strong ventilation!

PETG:Cutting is challenging. Its melt viscosity is high and it is very easy to melt and draw or carbonize. The suitable parameter window is particularly narrow, and it will melt severely if it is slightly wrong. Although it can cut out tough parts, if you want to cut well, you have to adjust the parameters repeatedly to try and error. In many cases, it may be more worry-free to useCNC milling.

PLA (common material for 3D printing):You can try to cut thin sheets (<1mm). But it is not very good if it is slightly thicker. The melting point is low, and it is easy to over-melt with slightly higher energy, resulting in rough edges and blistering. It is not recommended for precision parts.

🚫 Red Light District: Don't touch it! Dangerous!

PVC (chlorinated polymer ≥56%):This is an absolute restricted area! Decomposition at high temperatures releases highly toxic hydrogen chloride (HCl) gas (released >15ppm), which seriously endangers personnel health and will corrode your laser machine lenses and internal parts. Stop immediately when you see PVC materials! No matter how urgent the customer's needs are,JS refuses such processing.

Polycarbonate (PC):Cut with CO₂ laser. Too risky! It absorbs heat very well and can easily burn directly, causing violent melting, yellowing, and producing a lot of carbon smoke and toxic smoke. Even thin sheets (<1mm) can only barely draw a line, and the effect is far worse than cutting with a knife or processing with amilling machine. Don't make trouble for yourself.

Glass fiber/carbon fiber reinforced plastic:The resin will burn, and the reinforcing fiber will not only be cut continuously, but also produce a lot of irritating and harmful dust, and the PM2.5 concentration is >1200μg/m³ (40 times higher than the industrial standard), which seriously pollutes the machine and the environment.

Laser cut plastics, it is safest to identify acrylic, acetal, and polyester film. ABS, PETG, and PLA should be tried with caution.Stay away from PVC,polycarbonate, and glass fiber/carbon fiber composites!

"Choosing the right material is the key to safe and efficient processing. If you are not sure whether the material at hand can be cut, feel free to contact JS Company. Our mature online Laser cutting services can help you check and come up with a solution!"

Actual Case Analysis: Rapid Prototyping vs. Terminal Products

No matter how good the theory is, it depends on how it is actually done. Today I will share with you a real customer's smart home controller shell project to see how we choose materials and processes at different stages.

Case: Smart home controller shell development

Project background:The customer wants to make a shell for a new smart home controller. The project is divided into two steps:

Rapid visualprototyping:Rapidly make a 1:1 model. The core requirement is to accurately present the appearance (especially the transparent display window and frosted texture) for design confirmation.
Small batch functional prototype:Make about 10 sets of shells, which must be strong enough to simulate daily use (such as button pressing, accidental falling), and do functional testing for the internal team.

Phase 1: Visual Prototype

Core customer demands:Fast delivery, controllable cost, highly realistic appearance (clearness of transparent window, texture of frosted body).

JS solution: Laser cutting acrylic (PMMA).

Why choose it?

Good appearance:Transparent acrylic is used as the window, and the cut edge is clean and bright, without secondary polishing. Frosted black acrylic is used as the body, and the texture looks almost the same as the final product concept.
Extreme delivery:Acrylic is one of the most efficient plastics for laser cutting. The customer confirms the drawing in the morning, and we can deliver the prototype to him in the afternoon. This is critical for rapid iteration of design.
Cost-friendly (single piece/small batch):For single-piece or very small batch visual models, the startup cost and unit cost of laser cutting are much lower thaninjection molding. The price advantage of laser cutting is very obvious, especially suitable for the verification stage.

Phase 2: Functional Prototype

Core customer demands:Provide 10 sets of shells with sufficient strength and toughness for functional and durability testing in real environments.

The customer's initial idea:Can laser cutting of ABS sheet be used to make it?

JS's professional analysis and suggestions:

Why is laser cutting of ABS not recommended?

We explained to the customer: Although it is technically feasible, there are significant problems with laser cutting of ABS.

Poor edge quality:Laser cutting of ABS is easy to melt, the edges are sticky, carbonized, and burred, the surface is rough and the appearance is poor.
Hidden internal injuries:The high-temperaturecutting processwill generate stress inside the material, making the parts brittle, and the actual strength is far lower than the theoretical value of the material itself. When you drop it, it may crack as soon as it falls, but this does not mean that the ABS material itself is not good, it is the "internal injury" caused by the process. This will distort the test results.
Strong odor and smoke:Strong ventilation is required, and the processing environment is not friendly.

JS recommended alternatives:

Option 1: CNC processing of ABS sheet.

Advantages: The processing precision is extremely high, and the strength and toughness of the ABS raw material can be fully retained, and the performance isclosest to the final injection molded parts.
Consideration: The cost is relatively high, especially for small batches (10 sets), and the processing time is also longer.

Option 2: FDM 3D printing ABS (finally adopted option).

Advantages:

Found the best balance between strength, cost and speed. FDM-printed ABS parts have good toughness and can better simulate the impact resistance of injection molded parts. The cost is lower than CNC and the speed is faster.
The most important thing is that if a smalldesign problemis found during the test (such as a buckle is too tight), the design file can be modified and printed again immediately, and the adjustment is super flexible.

Consideration:The surface has layered lines and is not as smooth as CNC or injection molded parts, butthe functional test is completely acceptable.

Value-added service:We also used laser cutting ofhigh-precision Mylar (polyester film)insulation gaskets to ensure the safety of the circuit board inside the customer's controller.

Results:

The customer first locked the appearance design with an ultra-fast acrylic laser prototype without any detours. Then, we successfully completed internal testing with a3D printingABS functional prototype, exposing and correcting several minor structural problems in advance. The entire process was seamless, efficient and reliable, saving customers a lot of trial and error time and potential costs.

Key revelation:

The impact of different materials and processes on part performance is real, especially when subjected to external forces. Take a look at the difference in the performance of the following key indicator - bending stress (the ability of the material to resist bending deformation) after processing:

Material	Workmanship	Bending stress (MPa)	Suitable stage	Core advantages
Acrylic (PMMA)	Laser cutting	70	Visual Prototype.	Speed, cost, surface effect.
ABS	Laser cutting	30	Not recommended.	High internal stress leads to a significant decrease in strength.
ABS	CNC machining	45	Functional prototype/small batch.	Highest intensity and high precision.
ABS	FDM 3D printing	40	Functional prototype/small batch.	Resilience, balanced cost and speed, and flexibility.
PC	Injection molding (target)	95	Final mass production.	High strength and toughness.

Note: The bending stress values in the table are typical ranges. The specific values are affected by material grades, process parameters, part design, etc. The key is to see the trend difference.

There are different ways to make products at different stages.Laser cutting is a powerful tool for "looking good"(especially acrylic), with fast speed and low cost. But to make durable functional parts, you have to weigh the strength, cost and flexibility of CNC processing and 3D printing.

Don't let the process limit the design, and don't let the material drag down the test. At JS, we not onlycut materials, but also know how to select the best material processing combination according to your project stage and goals. Next project, let's talk about your needs? We will help you plan the best path!

FAQ - Answer Your Last Question About Plastic Cutting

How thick can laser cut plastic?

This mainly depends on the power of the machineand the type of plastic you want to cut. Take the most common acrylic as an example. Our 130W laser machine can generally cut through 20 to 25 mm (about 1 inch) thick boards smoothly.

But if you are cutting materials such as ABS or Delrin, the thickness that can be cut will be significantly smaller. It should be noted that if the plate is too thick and exceeds the ideal cutting range of the machine, the cut bevel will be more obvious and the edge may not be smooth and straight.

In actual work, when we encounter particularly thick workpieces, we usually prepare different machines and methods to deal with it according to its specific thickness to achieve the best results.

How to determine whether an unknown plastic is PVC?

Don't guess blindly, test it yourself! -Use the Beilstein test(also called the copper wire chlorine test method):

Be careful: Be sure to operate in a ventilated place and wear protective gear (gloves, goggles).
Steps: Find a clean copper wire, burn it red with a spray gun, and stick a little plastic sample on it while it is hot (let it melt and stick). Then put the copper wire with plastic back into the flame and burn it.
Look at the results: If the flame turns green, it means that the plastic contains chlorine, which is probably PVC!Never use a laser to cut this material,because chlorine will produce harmful gases when it is heated. The principle is simple: chlorine will make the flame appear green.

Can fiber laser cut plastic?

Usually not, or the effect is very poor.

Why?

The 1.06-micron wavelength of the fiber laser is mainly absorbed by metals, but most plastics are almost "transparent" to it. The energy passes directly through, and not much remains in the plastic to heat it.
Although some plastics have special absorbers added to allow fiber lasers to mark them, if you really want to cut through and cut well, you still have to rely on CO2 lasers. Its wavelength (10.6 microns) is much easier for plastics to absorb, and the energy utilization rate is high, which is a more reliable choice for cutting plastics.

Where can I find plastic laser cutting services near me?

You can search for "plastic laser cutting" to find a local service provider, but a faster and more worry-free way is to use online Laser cutting services like us. You upload the design file directly, select the material thickness and type, and the system will immediately give you a clear Laser cutting price. We have equipment of different powers, common plastic sheets in stock, accuracy and speed are guaranteed, and it is convenient to customize on demand no matter where you are.

Summary

Laser cutting plastic has powerful capabilities, but successful application is inseparable from professional knowledge and safety awareness. The core is: a deep understanding of the interaction between different plastic materials and lasers is crucial, and safety is always the first priority. The rightmaterial selectiondirectly determines the cutting effect, equipment life and personnel safety.

No need to take risks in material selection. JS team provides you with professional support:

Professional material consultation:I have been in this industry for many years and know best which plastic is suitable for laser cutting. You tell us your needs, and we recommend the best materials based on our experience to ensure operational safety and cutting quality.
One-stop customization service:If you needcustom laser cuttingmanufacturing, please upload your CAD file and our system will give you a real quote immediately. Our engineering team will also review your design for free to ensure that the most appropriate process and materials are used for production.
Save time and effort:From material recommendations, quotations to production, everything is done efficiently online. No matter where you are, you can easily get high-quality cut parts.

Safety is no small matter,and material selection is the key. Let our experience escort you,submityour projectonline now!

Disclaimer

The contents of this page are for informational purposes only.JS seriesThere are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information. It should not be inferred that a third-party supplier or manufacturer will provide performance parameters, geometric tolerances, specific design characteristics, material quality and type or workmanship through the Longsheng Network. It's the buyer's responsibilityRequire parts quotationIdentify specific requirements for these sections.Please contact us for more information.

JS Team

JS is an industry-leading companyFocus on custom manufacturing solutions. We have over 20 years of experience with over 5,000 customers, and we focus on high precisionCNC machining,Sheet metal manufacturing,3D printing,Injection molding,Metal stamping,and other one-stop manufacturing services.
Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it is small volume production or large-scale customization, we can meet your needs with the fastest delivery within 24 hours. chooseJS TechnologyThis means selection efficiency, quality and professionalism.
To learn more, visit our website:jsrpm.com

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