Frequently Asked Questions

1. When laser engraving with gradient, double phenomenon.

This phenomenon occurs when the slope of words carved smaller, usually the reason is "wide" setting slope too large, cause calculation errors, please set "wide" little slope.

2. If you only can move a graphic with one direction, please click "Shift" or "Ctrl" to recover.

3. PLT format cannot to engrave.

There are two reasons, one is the graphic is not closed, the other is graphic double. Please detect this phenomenon with "data detect" tools.

4. The size is not same with laser engraving and cutting samples. Open the item "laser engraving machine set", adjust the pulse.

5. The edge is irregularity when laser engraving.

The edge is irregularity maybe happen when you use the DSP laser engraver software, that means "burr", this is mainly caused by mechanical return clearance, this is the solution.

a. Draw a box (rectangular or square), set work mode for the laser engraving machine, the sculpture is 0.5 mm instead, then see laser engraving effect, theoretically, should be aligned, namely the odd interlaces did edge should be aligned, even did edge also should be aligned, only the odd and even did not have a little.

b. When you open "set laser engraving parameters", the parameters for different. laser engraving speed can be seen, the reverse gap is "0", you should adjust it as the matter of fact.

c. You can choose "single-track light" when best laser engraving effect needed. Not to chose the draw of "dual-engrave", but when you chose it, the efficiency would be lower.

6. The X-axis or the Y-axis not move.

a. Stir knob to chose the DC 5V, test the voltage between PULX（or PULY）and GND. Take Y axis as example, click the button of "up" or "down", the normal voltage is 2.8V, if it is not, we could confirm the controller was broken, please change the controller. If it is, please go to next step.

b. Exchange the output terminal of the two drivers, then press "Up" or "Down" button; if X axis works normal, it means there is something wrong with the motor on Y axis, please change a new one; if X axis doesn't work, it means there is something wrong with the driver on Y axis, please chance it.

7. X Axis and Y Axis work in only one direction.

a. Test the voltage between the DIRX and GND after pressed the multimeter into grade 5V; take the X Axis for example, press "left", then press "right" to see if there is some change on high level (>2.8V) and the low level(<0.8V); if not, the control card is broken and need to change a new one.

b. If with change, please check the driver; if works normal, please change the driver on Y Axis.

8. NO Ray.

Test the voltage between the LAS and GND after pressed the multimeter into grade 5V; press "fixed fire" in the control panel, to see if there is some change on high level (>2.8V) and the low level(<0.8V); if not, the control card is broken and need to change a new one. Also set up the time of fixed fir as 0 millisecond, which is in the PAD03 menu.

Adjust the power from 0%~100%, enter and press "fixed fire" button, then test if any change between the DA1 and GND from 0V to 5V; if not, the control card is broken, please change it; if both with, it means there is something wrong with the laser power supply.

1. The machine and the computer must have a good grounding.

2. Open the cutting software, click the file menu, communication settings to receive and send the buffer time is changed to 5 or 10.

3. The replacement of the data line or motherboard.

According to the same direction of the panel button, the laser cutting machine appears to be turning and reversing and motor power can not be locked.

1. First disconnect all power supply, the high pressure head with cotton cloth to wipe clean. (gentle scrub)

2. Cut off the broken pipe, re received the laser tube. And bundled with a tie.

3. The high voltage line (high pressure line with 7 silver thread, one less).

4. The fan will dry high pressure wet place, after half an hour, and then boot.

1. CNC router spindle rotation sound is not normal

a. The drive is set incorrectly.

b. Check whether the cooling water circulation.

c. There are problems with the spindle (bearing damage).

d. If the noise when loaded knife, normal, replace the tool without tooling.

2. CNC router spindle hot or noisy:

a. Check whether the cooling water circulation.

b. Check whether the bearing problem.

c. If loaded knife noise, without tooling normal, replace the tool.

3. CNC router spindle cooling water does not flow:

a. Check the coolant pump is working properly.

b. Check whether the water flow, the water from the spindle joint apart, blowing to the other side of the steam gun from one side or the connector on the spindle with a needle penetrating.

4. Motor reversal:

Check the motor cable is phase output UVW terminal ends of any exchange.

1. Roughness

Laser cutting cross section will form a vertical lines, the depth of the texture of the cut surface of the roughness of the cut surface, the more shallow lines, the more smooth cut section. Roughness not only affects the appearance of the edges, but also affect the friction characteristics, in most cases, it is necessary to minimize the roughness, so the more shallow texture, the higher the quality of the cut.

2. Verticality

If the sheet thickness exceeds 10mm, the verticality of cutting edge is very important. Away from the focus, the laser beam becomes divergent, according to the location of the focus, cutting to the top or bottom of the variable width. Cutting edge off the vertical line of a few millimeters, the edge of the more vertical, the higher the quality of cutting.

3. Cutting width

Kerf width generally does not affect the cutting quality, only in the internal components formed special precision contour, cutting width is important. This is because the cutting width determines the contour of the minimum, when the plate thickness increases, the cutting width also increases. So want to guarantee the same high precision, no matter how much the width of the cut, the workpiece in the laser cutting machine processing area should be constant.

4. Lines

High speed cutting thick plate, the molten metal will not appear in the vertical laser beam below the incision, but will be sprayed out at the laser beam side. As a result, the curved lines are formed on the cutting edge, and the lines are closely followed by the laser beam. In order to correct the problem, the feed rate can be reduced at the end of the cutting process.

5. Burr

Burr formation is a very important factor to determine the quality of laser cutting, because the removal of burr need extra work, so the amount of burr is serious and how much is able to directly determine the quality of cutting.

6. Material Deposition

Laser cutting machine before the beginning of melting and perforation of the workpiece surface with a layer of oil on the surface of a special liquid. Gasification and all kinds of materials, the material does not need to use the wind to blow the cut, but the upward or downward discharge also can form the deposition on the surface.

7. Sag and Corrosion

Sag and corrosion have adverse effects on the surface of the cutting edge, affecting the appearance. They appear in the error of the cut which is generally supposed to be avoided.

8. Heat Affected Zone

In laser cutting, the area near the notch is heated. At the same time, the structure of the metal changes. For example, some of the metals can be hardened. The heat affected zone refers to the depth of the area that is changed by the internal structure.

9. Deformation

If the cutting makes the component heat, it will deform. This is particularly important in fine processing, because the profile and connecting pieces are usually only a few millimeters wide. Control of laser power and the use of short laser pulses can reduce the parts to become hot, to avoid deformation.

Laser-cutting acrylic is one of the latest additions to our technological advancement that enables an efficient fabrication process of acrylic sheets and offers unparalleled precision in engraving, carving, or shaping them. This high-powered tech opened a world of creative possibilities.

But, today we are not going to praise the laser cutting of acrylic with what it can do. Rather, in this post we will be exploring the safety considerations of this tech and find out if it is toxic or not. We will also deliver safety measures and guidelines to follow before taking your project to the field.

The importance of understanding the safety considerations and following them is crucial. Let’s find out whether and how effectively the laser cutting acrylic revolutionized manufacturing industries.

A Brief Overview of Laser Cutting Acrylic

Laser cutting acrylic uses high voltage concentrated laser beam to cut through the materials. It offers a wide range of applications. The laser beam precisely cuts through or engraves acrylic sheets. This is way better than traditional milling or sawing methods. Efficient productivity and ease of usability make laser-cutting acrylic sheets popular these days.

Utilizing the intense heat generated by the laser cuts and shapes the material with smooth finishing and clean edges. Laser cutter offers superior accuracy to the task.

Understanding Safety Considerations and Importance

This newly added tech is undoubtedly more beneficial than any traditional milling and cutting methods. However, laser cutting acrylic also leads to potential hazards and safety risks. Today, our primary concern is the safety considerations and importance of those laser cutting acrylics.

Safety considerations in laser cutting acrylic are crucial. Lack of safety measurement will cause several hazards, such as health hazards, inhalation difficulties, eye injuries, skin irritation sensitization, and so on.

To avoid any unwanted experience follow these rules and make sure safety features are enabled.

☑ Proper ventilation is very important at work. The process creates fumes and gasses. Direct inhalation exposure can cause severe health issues within days.

☑ A complete PPE set can save you from many long-term physical diseases due to working with the laser beam. A proper PPE setup features organic vapor cartridges and safety goggles to protect against inhalation of fumes and potential eye damage from laser radiation.

☑ Make sure regular maintenance to maximize efficiency and performance. This will also save you from any potential machine malfunction or accidents.

☑ Emphasize the training and education of the operators. With proper knowledge and expertise, an operator can save the machinery along with him from any potential disabilities.

☑ Practice and ensure regulatory compliance provided by legal authorities.

Now, safety considerations bear great importance and significance due to probable hazardous incidents. Therefore, STYLECNC recommends prioritizing the safety steps to attain physical and financial safety on top.

Chemicals Released During Laser Cutting

Laser cutting uses high-voltage electric power to generate high-temperature heat. The concentrated laser beam then vaporizes the material with a predetermined path by a CNC software system and shapes the item accordingly.

In this whole machining process, a few chemicals and bi-products are produced as waste. Here, we have given a brief look at the chemicals produced during laser cutting acrylic.

Methyl Methacrylate (MMA)

The properties of Methyl Methacrylate and the health effects due to this chemical exposure are given below.

• Methyl methacrylate is a colorless liquid with a sweet odor

• Commonly used in acrylic plastics, adhesives, coatings, and resins production

• Skin contact can cause irritation, redness, and dermatitis for skin-sensitive personnel

• Even a short-time exposure to concentrated MMA can cause respiratory tract

• MMA is also considered a potential carcinogen

Now the exposure limits and regulations in laser cutting acrylic are necessary to learn and follow.

OSHA and ACGIH established exposure limits and guidelines for MMA to protect workers from diverse health effects. The OSHA permissible exposure limit (PEL) for MMA is 100 parts per million (ppm). The ACGIH threshold limit value (TLV) for MMA is 50 ppm as an 8-hour TWA.

Formaldehyde

Knowing the health hazards and carcinogenicity of Formaldehyde will certainly help keep you on a safe track. It is a colorless gas with a distinct odor. Health hazards prone to take cause are likely,

• Inhalation of the gas can irritate the eyes. Besides, the nose, throat, and respiratory tract are common hazards of the exposure

• Repeated and long exposure to Formaldehyde is responsible for severe health diseases like asthma, and bronchitis, as well as allergic reaction

• The International Agency for Research on Cancer (IARC) and the National Toxicology Program (NTP) classified Formaldehyde as a known human carcinogen

To reduce hazards due to this chemical substance regulatory guidelines are established by OSHA and ACGIH.

The OSHA permissible exposure limit (PEL) for Formaldehyde is 0.75 parts per million (ppm) and the ACGIH threshold limit value (TLV) for Formaldehyde is 0.3 ppm as an 8-hour TWA. OSHA has established a short-term exposure limit (STEL) of 2 ppm as well for formaldehyde. This is crucial to know about the regulatory guidelines for all operators.

Hydrogen Cyanide (HCN)

This is a highly toxic element found during the production of materials with coating and additives. Specific coated acrylic products can produce HCN. During acrylic cutting high temperature of the laser can produce a decomposition product like cyanide.

The health risks of this chemical element are high. So, safety measures for acrylic laser cutting are a must.

Inhalation of hydrogen cyanide vapor can lead to symptoms such as headache, dizziness, nausea, vomiting, difficulty breathing, and in severe cases, loss of consciousness and death. To minimize the chances of any health issues ensure the following steps,

Proper ventilation system, and personal protective equipment (PPE), monitor performance, and train the workers with adequate knowledge.

Health Risks Associated with Acrylic Fumes

Neglecting the importance of safety considerations and not following them can cause severe physical harm. Working for a long time to exposure to HCN can cause death.

Respiratory effects

• Irritation and discomfort: Exposure to fumes and gas and inhalation of irritant substances such as Methyl Methacrylate and formaldehyde, can cause acute respiratory irritation.

• Long-term health implications: Chronic exposure to acrylic fumes causes respiratory diseases such as bronchitis, asthma, and chronic obstructive pulmonary disease (COPD).

Skin and Eye Irritation

• Contact dermatitis: Contact with acrylic fumes can lead to contact dermatitis. Symptoms of contact dermatitis may include redness, itching, swelling, and blistering of the skin.

• Eye irritation and damage: Exposure to laser radiation consistently can cause eye irritation and damage.

Safety Precautions for Laser Cutting Acrylic

Safety precautions are essential to reduce the chance of accidents while laser cutting acrylics. Follow the safety measures and ensure a safe work environment. Some important safety measures are,

☑ Make sure proper ventilation in the cutting area to remove fumes and gases.

☑ Install fume extraction equipment or local exhaust ventilation.

☑ Provide appropriate PPE to the operators and workers.

☑ Make sure the workers wear respirators with organic vapor cartridges to avoid direct inhalation of fumes and gases.

☑ Use safety goggles and protective gloves on working.

☑ Ensure routine inspection and maintenance check-ups of the laser acrylic cutting machine.

☑ Train operators and workers.

☑ Follow the instruction manual given by the manufacturer.

Regulatory Compliance and Standards

Relevant regulations and guidelines for regulatory compliance are made to ensure the safety of the health and workers of cutting acrylic. These standards are established and approved by the Occupational Safety and Health Administration (OSHA), the National Institute for Occupational Safety and Health (NIOSH), and the International Organization for Standardization (ISO).

The OSHA regulations are:

⇲ Hazard Communication Standard (HCS).

⇲ Respiratory Protection Standard.

⇲ Personal Protective Equipment (PPE).

⇲ Ventilation Standard.

NIOSH also features a couple of standard guidelines for workers engaged with laser cutting acrylic for exposure to both Methyl Methacrylate and Formaldehyde.

There are a few ISO standards as well to follow.

Best Practices for Safe Laser Cutting Operations

To ensure a safer laser cutting operation operators and owners must follow all the safety considerations and regulations we talked about. A few tactics to make sure workers are healthy and safe are given below.

Training and education for operators

Provide comprehensive training to your workers for laser cutting acrylic including setup, shut down, and operation. Make sure they are trained for emergency response.

Regular maintenance of equipment

Take routine inspections of machines and parameters. Check parts and components like laser sources, optics, cooling systems, and safety interlocks, to identify and address any signs of wear, damage, or malfunction.

Monitoring and testing for air quality

Do take regular ventilation checks and install essential equipment to make sure the environment and air quality are breathable.

Laser cutting technology has advanced the cutting methods and precision ever more than before. The cutting is done using a concentrated laser beam at high temperature. This technology is welcomed in almost every industry. The versatility of the machines makes laser cutting more popular and outstanding.

It features the usability of a wide range of materials to shape, carve, or engrave. But in particular, plastics require more attention while making a project with them. Yes, Laser cutting polycarbonate is possible. You just need to know how to find the best suit for your project and fix the machine properly with accurate parameters.

Today, we are going to discuss the versatility of laser cutting technology and how to use it most efficiently. We are also going to break down the fact if laser cutting polycarbonate is possible or not, and if possible how to do that. Let's dive into the mastery of manufacturing cutting tools.

What is laser cutting?

Unlike traditional cutting and sawing methods laser cutting introduces a high-temperature laser beam-cutting tool that offers the most precise and efficient manufacturing outcome. The laser is usually focused and controlled through CNC router machines.

There are two common types of lasers used for the job.

1. Carbon Dioxide (CO2) lasers and

2. Neodymium-doped yttrium aluminum garnet (Nd:YAG) lasers.

The CO2 laser is suitable for non-metals like wood, acrylic, and fabric. On the other hand, Nd: YAG lasers are used for cutting metals and are capable of higher power outputs.

Laser cutting is used on a wide range of materials (metals and non-metals). Currently, laser cutting is available for cutting, engraving, or shaping steel, aluminum, copper, wood, acrylic, plastic, leather, fabric, rubber, etc.

Is it safe to laser-cut polycarbonate?

Laser cutting polycarbonate can be done with caution since many plastics are not suitable to cut using heat. It is important to know what kind of plastic you are going to cut.

The thickness and material density also impact the cutting. All plastics are not recommended to be cut using a laser. Specifically talking about polycarbonate, they cut very poorly and often discolor and catch fire. Usually, this material is found as sheets. For some specific reason laser cutting polycarbonate is not recommended for all purposes.

Therefore, due to the lesser effectiveness of laser on polycarbonate, it is considered a poor choice to use laser cut. But if necessary and with better thickness laser cutting polycarbonate is possible. Let’s see what are the potential difficulties to face while laser cutting polycarbonate.

Challenges of laser cutting polycarbonate

Polycarbonate tends not to work out with the laser cutting method. Yet you can get your job done only by following precautions and proper steps. But first, let’s find out the various challenges to face while laser cutting.

☑ Generation of hazardous fume: High high-powered laser beam can generate toxic gases like carbon monoxide and hydrogen cyanide. In the absence of proper ventilation, this can cause severe health conditions.

☑ Material sensitivity to heat: Polycarbonate is sensitive to heat. Extra heat can cause this material to melt, burn, or undesirable surface.

☑ Potential for thermal stress and warping: Thermal stress is common with overheating laser beams. This often leads to discoloration and distortion of material. It also affects dimensional accuracy and fit of the final product.

☑ Difficulty achieving clean edges: Achieving clean and smooth edges is challenging while laser cutting polycarbonate. Initially, the edges are prone to melt and tend to regain their shape. Meanwhile, the edge loses smoothness and shape.

☑ Effects of additives and coatings: Polycarbonate sheets with additives and coatings come with more challenges. When the material is heated these additives and coatings produce additional toxic gases and bi-products.

Besides, the risk of surface damage, the complexity of parameters optimization, and regulatory compliance and safety standards are a few factors that face additional challenges.

The best way to cut polycarbonate

Unlike laser cutting, there are more effective cutting methods for polycarbonate. The best way to cut polycarbonate depends on several factors such as thickness, desired precision, etc. We have gathered a few ways considered most effective in cutting polycarbonate. Let’s find out which works best for you.

A. CNC Knife Cutter

B. CNC Router

C. Table Saw

D. Jigsaw

E. Score and Snap Method and

F. Waterjet Cutting

They are proven useful with fewer challenges and better precision to a certain extent.

Safety Precautions

Plastic materials are not eco-friendly materials for our environment. Yet versatile composition makes them useful in many industries. Cutting polycarbonate using laser cutting technology requires special safety precautions.

The safety precautions need to be improvised actively. Here are a few key safety considerations,

☑ Proper ventilation is a must to remove toxic gases and contaminants. Use an exhaust system to remove fumes effectively.

☑ Use the suitable equipment only to maximize the smoothness and accuracy of the shape.

☑ Try to use polycarbonate sheets specifically made to laser cut. Take necessary steps if additives or coatings are available on the sheet.

☑ Wear an appropriate PPE set at work. Make sure your PPE comes with gloves, masks, and protective clothing.

☑ Fire safety is very important in laser-cutting polycarbonate. Keep a fire extinguisher nearby. Keep the flammable objects at a distance.

☑ Dispose of plastic waste properly.

Tips to cut polycarbonate efficiently

Cutting polycarbonate can be difficult in certain work environments. However, a few tips can come in handy. Try them out to get better results.

1. Select the right tools

Choose the appropriate cutting tools based on the thickness of the sheet. Use a table saw on thin sheets and jigsaw for curved or irregular cuts.

2. Use proper cutting techniques

Fix the sheet properly on the bed to avoid chipping or cracking. When using table saw use clamps to secure the sheet. Using a jigsaw? Move it slowly and steadily.

3. Optimize cutting parameters

Considering thickness adjust the cutting speed, feed rate, and blade speed. Try different settings to find the optimal balance.

4. Minimize heat buildup

Avoid excessive friction using sharp-edge tools. This will reduce the overheating issue. Apply cutting lubricants or cooling agents for more effective results.

5. Protective measures

Wear proper PPE set and use a dust mask.

6. Clean up

Remove debris and wastage immediately. Use sandpaper to bring smooth and clean edges.

How to clean discolored polycarbonate after laser cutting

Laser-cutting polycarbonate usually results in discoloring. Not following the proper usage instructions results in this discoloration problem!

Now, what are you going to do once the product comes with discoloration? We have given you a few ideas that may improve the final result. You can follow them step by step to get rid of this unwanted condition.

⇲ Allow the material to cool

⇲ Gently remove surface debris

⇲ Prepare a cleaning solution

⇲ Apply the cleaning solution

⇲ Rinse thoroughly

⇲ Buff with polishing compound

⇲ Check and repeat if necessary

You can apply a protectant additionally to prevent future discoloration.

Fiber laser cutting polycarbonate

Fiber laser cutting is more popular among consumers for cutting polycarbonate. A suitable polycarbonate sheet can ensure an efficient cutting result. A proper parameter setup is also responsible to avoid overheating and prepare a smooth cutting action.

Follow the thermal precautions given at the top of the article and you are all good to go.

Post-processing is also a significant task to finally achieve a proper production. Follow the safety considerations available for laser cutting polycarbonate.

Laser cutting polycarbonate VS acrylic

Polycarbonate and acrylic are two different materials. In terms of applying similar cutting methods, both can result in contrasting. Let’s take a look at the similarities and dissimilarities of laser cutting polycarbonate and acrylic.

Laser engraving or laser cutting is to converge the laser beam into a small spot through a focusing mirror and project it onto the surface of an object. The focal point reaches a high power density. At this time, the irradiated part of the material is quickly heated and vaporized, and the laser beam and the material move relatively linearly, so as to realize laser engraving cutting plans.

When the laser engraving machine or laser cutting machine is working for a long time, the optical path will deviate, which will affect the cutting effect. Only the perfect cooperation of laser tube, reflecting mirror frame (A, B, C), focusing lens and corresponding adjustment device can achieve the best effect and process the best projects. This is the core part of using CO2 laser machine. Therefore, it is very necessary to check the laser beam path and adjust it regularly.

8 Steps to Adjust and Align CO2 Laser Beam Path:

1. Turn on the air pump, the air flow is discharged under the trolley, and the wires on the X and Y axis drives of the right control box are pulled away.

2. Turn on the machine switch, the LCD display on the operation panel shows "The system is starting, please wait ..." At this time, the machine is in the reset state, wait for about half a minute, then the LCD displays: File name: AAA Processing speed 100% processing Power: 100/100% Processing quantity 1 Delete. At this time, the machine is in the initial online state.

3. Stick a round cardboard larger than the lens in front of the first reflective lens and the second reflective lens.

4. Put a large cardboard in front of the laser head of the tube, press the fire button on the operation panel, the laser tube emits light, and adjust the laser to the first reflection by adjusting the front and rear positions of the laser tube bracket and the thickness of the rubber under the tube The middle of the lens.

5. Adjust the laser to the middle of the second reflective lens by adjusting the three screw shafts behind the first reflective lens. When adjusting the second reflective lens, the X-axis beam should be moved to the front and back, the point where the laser hits Be completely coincident.

6. Adjust the laser to the hole on the left side of the laser head by adjusting the three screw shafts behind the second reflective lens. When the laser head moves to the four corners of the worktable, the laser must hit the middle of the hole.

7. Focus adjustment.

Focal length refers to the distance (4-4.2mm) between the top of the cone head under the laser head and the surface of the material.

8. By adjusting the tightness of the three screws on the mirror above the laser head, the laser can be adjusted to the vertical angle to ensure the verticality of the cutting surface when cutting.