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As laser cutters vaporize parts instead of melting them, laser cutters undoubtedly produce fumes and smoke. Therefore, it is essential that only laser-safe materials are used (these materials do not contain harmful compounds such as chlorine and chromium that can be toxic when turned into a gas) so that damage to the machine, workers nearby, and the environment is prevented.

Another problem faced with laser cutters is that the extreme heat from the laser beam can spread into the part being cut, and this heat if not controlled can cause deformation. This is particularly an issue where large thermal differentials are experienced as large differences in temperature result in different amounts of expansion. Additionally, this intense heat can also affect the characteristics of the plastic being cut (such as tensile strength and density), which is why only thermoplastics should be used with laser cutters (thermoplastics are designed to be heated up, remolded, and then cooled).

To ensure the highest quality parts and precision across all manufactured plastic parts, Ponoko only selects the highest quality materials that have been specifically engineered for laser cutting. The years of experience that Ponoko has as a laser cutting service combined with expert machine operators ensure that every single part leaving Ponoko manufacturing facilities all conform to our strict quality parameters that include dimensional accuracy, precision, and material properties.

When deciding what material to use for a part, an engineer can be left with so many options across many manufacturers. Just a handful of the questions that an engineer needs to answer include ‘is the chosen material strong enough, ‘is it compatible with a laser cutter’, ‘how long will it last’, and ‘can I trust the supplier. This process alone can cost an engineer precious development time that would otherwise be spent on product design, testing, or delivery.

To help engineers with such challenges, Ponoko has a specially curated range of plastic materials that can help speed up the process of selecting an appropriate plastic for their custom laser-cut parts. All our stocked materials are engineered meaning that their material properties are tightly controlled and well documented (such as electrical conductivity, thermal conductivity, and density), and all materials are laser-safe meaning that they are all appropriate for our laser cutting services.

Furthermore, all materials stocked by Ponoko go through numerous quality assurance checks in-house, and all materials are sourced from reputable and traceable suppliers. As such, all parts manufactured with our stock exhibit excellent engineering qualities, precision, and accuracy. So much so that any two parts manufactured by us will be virtually indistinguishable, even if the parts have been purchased at different points in time. The importance of having this consistency is to not only ensure that manufactured parts perform as expected, but to also ensure that mass-produced parts exhibit minimal variation.

Even though a laser cutter could theoretically cut any plastic out there, only plastics that are considered laser-safe should be cut. This is because some plastics (such as PVC) contain compounds that, when vaporized, can present a very real danger. In the case of PVC, chlorine gas can be released during laser cutting which is not only bad for those working nearby, but can also damage the laser cutter itself through its corrosive properties.

Other materials can produce excessive amounts of smoke when vaporized, and this smoke can affect the performance of a laser cutter in numerous ways. For example, excessive smoke can leave residues on sensitive optical components (which must be kept clean) and this can affect the performance of the cutter. Another example is that the presence of too much smoke can block the path of the laser beam, and therefore degrade the cutting ability of the machine.

But trying to ensure that a material is laser-safe is not the easiest task to accomplish as plastics vary widely between different manufacturers with some adding additives to provide different features. As such, those looking for plastic stock need to check the contents of the plastic, confirm that none of the additives will introduce challenges, and then test the material for its laser-cutting characteristics.

Ponoko not only has years of experience in the laser cutting industry but also in material curation. Our team of specialized engineers know exactly what to look for when selecting new materials to add to our catalogue of over 200+ engineered materials, and this means that engineering customers can spend far less time selecting appropriate materials and more time designing their parts!

One of the best features of laser-cut plastics is that they are also very easy to engrave. As plastics are not hard like metals, they are easily vaporized with a laser beam, but plastics are also highly durable which allows for engravings to last for the lifetime of the part.

However, engraved plastic can be difficult to see, especially if the plastic is transparent (such as acrylic), but this does depend on whether the engraved area is cleaned to remove discoloration, left as is, and given a rough finish as well as the color of the plastic. Thankfully, engraved transparent parts can take advantage of side lighting to light up only engraved areas, and this makes them ideal for signs and decorative pieces.

If the contrast of a laser-engraved part needs to be increased, inks can also be poured into engraved channels. This allows for color graphics on laser-cut plastic parts, but controlling areas where color is present can be difficult.

A major advantage of laser-engraved plastic is that engravings are impossible to remove without abrasion. This is why laser engraving is ideal for security identifiers (such as serial numbers), and face plates in industrial areas where workers use thick gloves with debris. At the same time, laser engraving is done during the same manufacturing cycle as laser cutting, and this means that laser engraved designs are not only precisely positioned relative to the part, but the engraving stage doesn’t require additional manufacturing steps. This helps to keep the cost of laser engraving low while also making it suitable for mass production.