Acrylic is a favorite material for hobbyists and professionals alike, thanks to its durability, versatility, and ability to produce stunning, polished results. CO2 laser cutters are the go-to choice for acrylic projects because they deliver flame-polished edges and precise cuts, especially on clear acrylic, which diode lasers struggle with. This article explores the best CO2 laser cutters for acrylic projects in 2025, focusing on performance, ease of use, and value for hobbyists and small businesses. Based on hands-on insights and market research, we’ll help you find the perfect machine for crystal-clear results.

Why CO2 Lasers for Acrylic?

CO2 lasers, operating at a 10.6-micron wavelength, are ideal for acrylic because they align perfectly with the material’s absorption spectrum, ensuring efficient energy transfer. This results in clean, polished edges with minimal post-processing, unlike diode lasers, which can’t cut clear acrylic and often require multiple passes for thicker materials. CO2 lasers also offer:

• Flame-Polished Edges: Achieve smooth, glossy finishes without sanding.
• Precision: Cut intricate designs with tolerances as low as ±0.05mm.
• Versatility: Handle both cast and extruded acrylic, plus other materials like wood and leather.
• Speed: Cut acrylic faster than CNC routers or diode lasers, often at 15–25mm/s for 3mm sheets.

Key Features to Consider

When choosing a CO2 laser cutter for acrylic, prioritize these features:

1. Power: 40W–80W is sufficient for most acrylic projects, cutting up to 10–25mm thick. Higher wattage means faster cuts and thicker material capability.
2. Work Area: A bed size of at least 12"x8" suits small projects, while 20"x12" or larger is better for signage or batch processing.
3. Air Assist: Essential for clean edges by preventing flare-ups and clearing debris.
4. Software: Look for compatibility with user-friendly software like LightBurn or xTool Creative Space for easy design and control.
5. Safety: Enclosed designs, fume extraction, and emergency stops are critical for handling acrylic’s toxic fumes.
6. Cooling System: A reliable water chiller or cooling system prevents overheating during long jobs.

Top CO2 Laser Cutters for Acrylic Projects

Here are three top CO2 laser cutters for acrylic in 2025, selected for their performance, beginner-friendliness, and value, based on hands-on reviews and market insights:

1. xTool P2 (55W)

• Power: 55W
• Work Area: 600 x 308mm (23.6" x 12.1")
• Max Acrylic Thickness: 20mm
• Price: ~$4,299
• Why It’s Great: The xTool P2 is a standout for acrylic cutting, effortlessly slicing through 20mm clear or colored acrylic in a single pass. Its dual 16MP cameras and autofocus simplify setup, while batch processing and curved surface engraving make it ideal for small businesses. The xTool Creative Space software is intuitive, and LightBurn compatibility adds flexibility. Its enclosed design and built-in exhaust system ensure safety when cutting acrylic.
• Pros:
  • Cuts clear acrylic with ease, unlike diode lasers.
  • Large work area and fast 600mm/s engraving speed.
  • Smart features like dual cameras and batch processing.
• Cons:
  • Higher price point than budget models.
  • Mirrors/lenses may need adjustment after transport.
• Best For: Hobbyists and small businesses needing precision and versatility for signage, displays, or custom acrylic products.

2. OMTech 80W CO2 Laser Engraver

• Power: 80W
• Work Area: 500 x 700mm (19.7" x 27.6")
• Max Acrylic Thickness: ~25.4mm
• Price: ~$3,000
• Why It’s Great: The OMTech 80W is a powerful choice for cutting thick acrylic (up to 1 inch) with clean, polished edges. Its large bed accommodates full acrylic sheets, and the industrial water chiller ensures consistent performance during extended jobs. Compatible with RDWorks and LightBurn, it’s versatile for both beginners and professionals. The 4-way pass-through door allows for oversized projects.
• Pros:
  • Cuts very thick acrylic in a single pass.
  • Spacious work area for large signage or panels.
  • Affordable for its power and features.
• Cons:
  • No built-in camera for real-time alignment.
  • Larger footprint requires dedicated space.
• Best For: Professionals or serious hobbyists working on large-scale acrylic projects like LED signs or architectural models.

3. Glowforge Aura

• Power: 30W
• Work Area: 305 x 305mm (12" x 12")
• Max Acrylic Thickness: 6mm
• Price: ~$1,199
• Why It’s Great: The Glowforge Aura is a compact, beginner-friendly CO2 laser cutter with a plug-and-play setup. Its cloud-based software and built-in camera make material alignment and operation a breeze, even for those new to laser cutting. It cuts acrylic up to 6mm with polished edges and is perfect for small, detailed projects. The optional air filter allows indoor use without external ventilation.
• Pros:
  • Extremely easy to use with minimal setup.
  • Compact and safe for home studios.
  • Cloud software simplifies design for beginners.
• Cons:
  • Limited to thinner acrylic (up to 6mm).
  • Cloud software requires reliable Wi-Fi.
• Best For: Beginners or crafters focusing on small acrylic projects like jewelry, ornaments, or home decor.

Tips for Cutting Acrylic with a CO2 Laser

1. Use Cast Acrylic: Cast acrylic cuts cleaner and polishes better than extruded acrylic, which may melt unevenly.
2. Optimize Settings: For 3mm acrylic, try 30–40% power at 15–25mm/s with air assist on. For thicker acrylic (8–10mm), use 70–80% power at 4–6mm/s. Always test on scrap material first.
3. Remove Protective Film: Peel off any protective film before cutting to avoid residue or burning.
4. Ensure Proper Ventilation: Acrylic fumes are toxic. Use a strong exhaust system or fume extractor to vent fumes outside.
5. Maintain Focus: Use a focus tool or autofocus feature to ensure precise cuts and avoid rough edges.
6. Clean Regularly: Wipe the lens and mirrors to maintain cut quality and prevent power loss.

Common Pitfalls and Fixes

• Melted or Rough Edges: Increase speed, reduce power, or check focus alignment. Ensure air assist is on.
• Yellowing/Burning: Use cast acrylic and enable air assist to minimize heat buildup.
• Incomplete Cuts: Slow down the speed or increase power for thicker materials.

Conclusion

For crystal-clear acrylic cuts, CO2 laser cutters are unmatched in precision and efficiency. The xTool P2 is the top choice for versatile, high-powered performance, ideal for serious hobbyists and small businesses. The OMTech 80W excels for large, thick acrylic projects, while the Glowforge Aura is perfect for beginners tackling smaller crafts. By choosing a machine that matches your project needs and budget, and following proper settings and safety practices, you’ll achieve professional-quality results with ease.

Happy cutting!