Laser Cutter Intro

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We often design prototypes, in OnShape, that can quickly be cut out of 1/4" plywood on the laser cutters.

Our laser cutters have a maximum working area of 24" by 18"

Instructions

Design and Export

Design the prototype in OnShape
Create a drawing without a border nor titleblock
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1. Right click on any part in the parts list, choose Create Drawing
2. Choose Custom Template
3. Choose “Do not include” for both Border and Titleblock, click Ok
4. In the Insert view dialog make sure the View scale is 1:1
5. You may need to change the View orientation to see the side of the part for cutting
6. Click to place the part anywhere on the drawing sheet (we can move it later)
7. OnShape assumes we want to have projected views. We do not need to place projected views, press escape to cancel the projected view.
Be make sure our drawing size matches our stock size.
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1. Open the Sheets pane
2. Right click the sheet (probably Sheet1) and choose Properties
3. In the Sheet properties dialog, change the Size to custom
4. Set the width and height to match your stock. Usually to 24 in wide and 18 in in height
Additional parts can be added to the sheet with the Insert View tool
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1. Click the Insert View tool
2. In the Insert view dialog click the Insert button
3. Choose another part
4. Be sure the View scale is 1:1
5. You may need to change the view orientation
6. Click to place
7. OnShape assumes we want to have projected views. We do not need to place projected views, press escape to cancel the projected view.
8. Repeat these steps for each unique part
If you need more space, additional sheets can be created.
1. From the sheets pane, click the add sheet button.
By this point you should have all the parts on various sheets. Export each sheet to SVG.
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1. Change to the first sheet
2. Right click on the drawing tab at the bottom, choose Export…
3. Set the format to SVG, Click Export
4. Repeat for each sheet

Preparing the file

The laser will Cut any line that is exactly .001" wide, all others are engraved.

This tool will automatically convert all lines to .001" for cutting https://svg2laser.fly.dev/

Manual Process

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The following steps assume you are on a computer connected to the laser

Set Cutting and Engraving speeds

Open the PDF with Adobe Acrobat Reader
File > Print
Select the Epilog Laser from the list of printers
Click Properties to open the laser configuration window
- 1 - Be sure Auto Focus is selected
- 2 - Combined is sufficient unless you want to be sure to only do one type of operation (vector=cut and raster=engrave)
- 3a - Set the Speed and Power for the Raster (Engrave) operation
- 3b - Set the Speed, Power and Frequency for the Vector (Cut) operation
- 4 - Set the Page size to match stock size (often 24" horizontal x 18" vertical)
- Click OK

Consult the Laser Material Settings or the abbreviated table below for our 60W, CO2 Laser determine your power, speed and frequency/DPI for your material.

Material	DPI/Freq	Speed	Power
Acrylic
Cutting 1/8"	100 Hz	20	100
Cutting 1/4"	5000 Hz	12	100
Plastics
Engraving	300 DPI	90	25
Plastic (2 layer engraveable)
Engraving	300 DPI	90	65
Cutting 1/8"	5000 Hz	30	85
Wood
Engraving	300 DPI	40	100
Cutting 1/4"	500 Hz	20	100

Power on, Load Material and Cut/Engrave

Turn On the Laser, Air Assist and Fume Extraction
1. Laser Power: Switch on Left side
2. Air Assist: Switch on compressor pump
3. Fume Extraction: Time Dial on wall (takes ~30 secs to start)
Place your material in the upper left of the laser engraver bed

You should hear loud hissing and fan whirring sounds! If not: Stop and ask for help!

Make sure your project looks correct on the print preview
Click Print, and that your job name should appear on the laser display
To start, push the green print button on the laser

STAY NEXT TO THE LASER WHILE PRINTING!

Done!

Material Notes

When cutting wood, multiple passes may allow cutting of thicker materials. Using Color Mapping you can adjust the focus point between passes down to the center point of the cut for the best results.

When cutting acrylic, adjusting the standard focus distance so it is closer to the lens by about .080” (2 mm) will produce better edge quality when cutting 1/4” (3mm) acrylic and thicker. Two passes can be used for cutting thicker materials.

There are two types of acrylic: cast is better for engraving (it creates a frosted look when engraved) and extruded acrylic produces a much better flame polished edge.

Based on the fantastic Inkscape tutorial from the Tulane makerspace http://makerspace.tulane.edu/Uploads/InkscapeTutorial.pdf

Laser Cut a Box