Acrylic is one of the most popular materials for CO2 laser cutting, producing smooth edges and polished finishes that require minimal post-processing. But achieving perfect results requires the right settings, techniques, and equipment. This comprehensive guide covers everything you need to know about cutting acrylic with a CO2 laser, including optimal power/speed settings, common mistakes to avoid, and the best machines for the job.

Why Use a CO2 Laser for Acrylic?

CO2 lasers (40W-150W) are ideal for acrylic because:
✔ Creates flame-polished edges – No sanding needed
✔ Cuts with extreme precision – Tolerance within ±0.1mm
✔ Works with cast & extruded acrylic – Unlike diode lasers
✔ Faster than CNC routers – Cuts 3mm acrylic at 15-25mm/s

Optimal CO2 Laser Settings for Acrylic

Cutting Settings (By Thickness)

Engraving Settings

• Speed: 300-500mm/s

• Power: 10-20% (for surface etching)

• DPI: 300-600 (higher = smoother gradients)

Pro Tips for Flawless Acrylic Cutting

1. Use Cast Acrylic (Not Extruded)

   • Cast acrylic cuts cleaner and polishes better

   • Extruded acrylic may melt unevenly

2. Remove Protective Film Before Cutting

   • Film can burn and leave residue

3. Adjust Focus Precisely

   • Use a focus tool or manual Z-axis adjustment

4. Optimize Air Assist

   • Prevents flare-ups and improves edge quality

5. Avoid Overheating

   • Let the laser cool between long jobs

Best CO2 Laser Machines for Acrylic

1. Best for Small Shops: OMtech 60W (MF1624-60)

• Price: $4,200

• Max Acrylic Cut: 10mm

• Pros: Reliable, good software support

2. Best for Production: Thunder Laser Nova 80W

• Price: $7,500

• Max Acrylic Cut: 15mm

• Pros: High speed, rotary attachment compatible

3. Best Industrial Option: Epilog Fusion Pro 120W

• Price: $25,000+

• Max Acrylic Cut: 20mm

• Pros: Unmatched precision, low maintenance

Common Acrylic Cutting Problems (And Fixes)

❌ Problem: Melted or Rough Edges
✅ Solution: Increase speed, reduce power, check focus

❌ Problem: Yellowing/Burning
✅ Solution: Use cast acrylic, enable air assist

❌ Problem: Incomplete Cuts
✅ Solution: Slow down speed or increase power

Acrylic vs. Other Materials on CO2 Lasers

Final Verdict: Cutting Acrylic Like a Pro

A 60W-100W CO2 laser is ideal for acrylic cutting, balancing speed and edge quality. For best results:
✔ Use cast acrylic
✔ Apply correct power/speed settings
✔ Enable air assist
✔ Maintain proper focus

Need help choosing a laser? Comment with your project requirements for personalized recommendations!