Laser Cutting Services

Cutting Envelope: 24 x 24in

Maximum Cut Part Size: 23.9 x 23.9in

Laser Classification: Class 4 CO2 Laser

Laser Wattage: 200W

Part Clearance (Z-Axis): 3 Inches

Positioning Accuracy: +/- .002″/ft

Repeatability: +/- .0005″/ft

Straightness: +/- .002″/ft

Air Assist:  Compressed Air, Oxygen, or Nitrogen

Material Compatibility: Requires high energy absorption at 10.6µm wavelength, Non-reflective at 10.6µm wavelength, No chlorine gas emission (for safety)

Link to manufacturer's website

Plastics:

• ABS (acrylonitrile butadiene styrene), up to 0.125 inch thick – Discouraged Material: Poor cut quality
• Acrylic (also known as Plexiglass, Lucite, or PMMA), up to 0.5 inch thick 
• Delrin (POM, acetal), up to 0.25 inch thick 
• HDPE (High-Density Polyethylene), up to 0.25 inch thick – cut quality is poor (poor edge finish with melting at most thicknesses).  See King Starboard for alternative option.
• Kapton tape/film (Polyimide)
• King Starboard, Marine-Grade High density polyethylene (HDPE), up to 0.375 inch thick – Common Material
• Mylar (polyester)
• Nylon – Discouraged Material – Poor Cut Quality
• PETG (polyethylene terephthalate glycol), up to 0.125 inch thick (discoloration and/or melting at higher thicknesses)
• Polyethylene (PE) – melts badly
• Polypropylene (PP) – melts somewhat
• Teflon (PTFE, Polytetrafluoroethylene), up to ~0.025 inch thick
• Styrene/Polystyrene – Poor cut quality

Thin Metals:

• Stainless steel (up to 0.060″)  - Common material
• Spring steel (up to 0.060″)
• Cold-Rolled steel (up to 0.08”)
• Titanium (up to 0.04”)

Other Materials:

• Depron foam – often used for RC planes.
• EPM foam
• Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
• Cloth (leather, suede, felt, hemp, cotton)
• Magnetic sheets
• Paper
• Silicone Rubbers (may not contain chlorine) – up to 0.25 inch thick
• Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.) – we stock various thicknesses of birch plywood.

Kerfing refers to the intentional removal of material along a line (or other repeating pattern) to create flexibility in rigid materials. The "kerf" is the width of the material removed by the laser as it cuts, and by making a series of parallel cuts (kerfs) in a controlled pattern, it is possible to create flexible sections within otherwise stiff sheets. This technique is particularly useful in forming curved shapes from flat materials or adding articulation to components that require some degree of bending. Laser kerfing provides a high level of precision and repeatability, enabling tight tolerances and consistent results across complex geometries.

Joinery in laser-based manufacturing refers to the methods used to connect two or more parts together to form a complete structure. Laser cutting allows for the creation of precise, interlocking joints that can be fitted together with minimal gaps. Common types of joints include finger joints, tab-and-slot connections, and dovetail joints. The advantage of using laser cutting for joinery is the accuracy it provides, allowing for tight fits that can often be assembled without the need for additional fasteners or adhesives. This precision not only speeds up assembly but also contributes to the strength and aesthetic quality of the final product.

Finger-tip Joints

Finger joints are the basic joint for putting two flat plates together at a perpendicular angle to make a corner. It basically consists of tabs on the mated sides that interlock. The tabs are usually as long as the material is thick to make a nice, clean seam.

Mortise and Tenon Joints

Mortise and tenon joints are very similar to finger joints, except the “fingers” on one piece of material stick through holes in the other piece of material. These are useful for creating “T” like structures and easily mounting internal support beams for more complicated laser cut structures.

Slotted Joints

Slot joints are another pretty common type of simple laser cut joint. The two connecting pieces each have slots cut halfway through them, which can slide into each other to form “X” like structures out of the laser cut material.

Dovetail and Jigsaw Joints

Dovetail joints and jigsaw joints are usually used in laser cutting to mount two materials flush to one another, with even top and bottom surfaces. Although these are more widely used in woodworking, they can come in handy if you’re looking for a certain effect.