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Of all materials that can be cut using a laser, cardboard is one of the easiest thanks to its thin construction. Card itself is a paper material, and as paper is a material that burns easily, lasers have little trouble cutting cardboard. While cardboard can be cut using a wide range of methods (such as knives, scissors, and saws), laser cutting offers the ability to cut extremely complex shapes with great precision, speed, and repeatability. However, operators of laser cutters have to keep in mind that cutting cardboard produces a large amount of smoke which can interfere with the laser beam. As such, ventilation is very important when cutting cardboard.

Engraving cardboard is a very easy task thanks to cardboard being a paper-based material. This means that it is very easy to burn, and engraving cardboard involves the burning of an extremely small layer on the surface of the cardboard. The burnt cardboard creates an extremely strong contrast between the bulk material and the engraved pattern (assuming that the cardboard being engraved is a light color), and the high speed of engraving cardboard makes it an ideal method for custom designs and graphics. However, engraving cardboard can present challenges that the operator has to take into account. One challenge, in particular, is getting the laser energy correct; too much energy and the laser can burn right through the cardboard. Too little energy and the cardboard won’t burn.  

Cardboard is a fantastic material to work with and use in projects, both prototypes and final products, but it does have its limitations. The first point of concern when using cardboard is that it is not waterproof which limits its use to applications that will not experience any moisture. When cardboard becomes wet (or even moist), it becomes structurally weak and thus unable to hold its shape reliably or provide protection if being used in packaging. The second point of concern is that cardboard is structurally weak. Cardboard is great for producing scale models, boxes for transporting goods, and even prototypes of enclosures, but its weak structural properties make it unreliable for anything structural. Any application that needs to support weight should look at alternative materials such as MDF or plastic. The third point that engineers should consider is that cardboard is highly flammable (so flammable that it is often used as a fire starter in bonfires and fireplaces). This means that cardboard should not be used in any application that may contain a source of ignition such as high voltages, heaters, and flames.

Of all materials that could be laser cut, cardboard is arguably one of the cheapest (next to card and paper). The sheer quantity of cardboard that is manufactured and its many applications sees cardboard prices far lower than the most common plastics and metals. But the cost savings of cardboard extend beyond the material itself; the ability to easily cut it with a laser cutter makes it even more appropriate for mass production. Laser cutters can cut shapes out of cardboard that is simply not possible with CNCs, knives, or scissors. Such mechanical methods also require that the cardboard be mechanically secured, and this can make cutting small details and shapes extremely challenging. The speed at which laser cutters operate makes most other production-level methods look antiquated.

Laser cutters are limited on the thickness of material that they can cut. While Hollywood shows laser beams as being perfect parallel beams that cut over great distances, the truth is that laser beams diverge. Material that is at the focal point of the laser beam will cut the fastest and cleanest, but material that falls outside the focal point will have a wider than anticipated cut that will be of lower quality. When it comes to cardboard, Ponoko can cut cardboard that is up to 0.26 inches in thickness, and the types of cardboard that Ponoko offer includes corrugated, coaster board and mat board. These materials are also available in a range of different colors and textures that allow them to be used in a wide range of applications.

Laser-cut cardboard can be used in any application that requires a high degree of precision, accuracy, and/or mass-production capability. One such example would be the prototyping of cardboard boxes with specific graphic designs. As boxes can be formed from a single 2D shape that is folded along specific lines, cardboard cut-outs can take advantage of the ability for Ponoko to make anywhere from 1 to 1000, and the laser engraving can be used to engrave designs during the same stage as the cutting. Another example of where laser cut cardboard would be advantageous is the creation of architectural concepts. CAD is the go-to environment for designing buildings and determining stresses in structures, but a scale model is typically made to impress potential investors as well as give the design a sense of reality. The precision of laser cut cardboard will create designs that are clean and professional while engraving can be used for features such as windows and logos. Laser-cut cardboard can also be used for creating prototype 3D structures that are built up with layers. Each layer is cut individually on a laser cutter, and these are then stuck together to create a 3D model in a near-identical fashion to 3D printing.

Laser-cut cardboard is fully recyclable making it an ideal product for those looking to add an environmental edge to their design. The non-toxic nature of cardboard also makes it ideal for disposal in composting facilities and can be advertised as not harming the environment.