Making Laser Cut Boxes: Choosing A Material

It’s important that you pick a suitable material for laser cutting.  The key aspects that you’re looking for is something that is cuttable, non-toxic, sized appropriately for the laser cutter, flat and has a consistent density.  Determining precise thickness of the material is also critical for your design in addition to being thin enough for the laser to cut within one or two passes.

You’ll be burning the material with the laser.  Glass and metal can be marked with laser, but it can’t be cut because the head spreads too quickly though the material.  Materials such as PVC or ABS will emit a toxic gas when burned.   If you’re not sure of the composition of the material you have, don’t cut it.  If you’re still not sure, check with your makerspace before putting your material in the laser cutter.  

Laser cutter beds vary by model.  The most common laser cutter that I’ve used is the Epilog Helix which has an 18” x 24” bed.  If your material is nice and flat, the laser will be able to maintain a constant focus over the whole material, making for a consistent cut.  Variations in density such as knots or voids will affect the consistency of your cut.

I recommend either wood or acrylic for box making.  I’ve found the best thickness is about ¼” or 5mm to 6mm.  Too thin, and the box won’t be strong enough, too thick and you’ll have a hard time getting the box to cut all the way through without requiring multiple passes on the laser cutter.