Acrylic is one of the best materials you can put under a laser. When it behaves properly, the edge comes off polished, engraving turns bright white, and parts drop out clean and precise.
When it doesn’t, you get melted edges, stress cracks, inconsistent engraving, and wasted sheets.
The difference is rarely the laser alone. It’s the combination of material type, thickness, file prep, and experience.
After years of in-house laser cutting in NYC, we’ve seen what works consistently — and what causes avoidable problems. This guide breaks it down clearly.
Why Acrylic Responds Differently Under a Laser
Acrylic does not burn like wood. It vaporizes.
When the laser hits acrylic:
- The material melts and vaporizes along the cut path
- The heat briefly polishes the edge
- Surface tension creates a smooth, glossy finish
This is why laser-cut acrylic edges often look flame polished straight off the bed. However, acrylic is also sensitive to internal stress and heat buildup.
What Is the Best Acrylic for Laser Cutting?
Cast acrylic is the best acrylic for laser cutting. It produces polished edges, engraves with bright white contrast, and responds consistently to laser heat. Extruded acrylic melts more easily and engraves with less clarity.
Cast vs Extruded Acrylic in Laser Cutting
Cast Acrylic
- Polished, glass-like edges
- Crisp white engraving
- Better for visible finished parts
- More stable under heat
Extruded Acrylic
- Lower cost
- Higher melt risk
- Duller engraving results
For professional laser results, we primarily recommend cast acrylic.
Fluorescent Pink laser cut components
What Thickness of Acrylic Cuts Best on a Laser?
We prefer .040" (1mm), 1/16", 1/8" and 1/4" sheets. They provide the cleanest cuts and strongest detail retention. Thicker sheets can be laser cut, but require more precise control.
Common Laser Cutting Mistakes
- Using extruded acrylic for engraving
- Overlapping vector paths
- Ignoring kerf in tight-fit parts
- Sending raster files for cut lines
How to Prepare Files for Clean Laser Results
- Vector cut paths (AI, PDF, EPS, SVG, DXF)
- Separate engraving layers from cut layers
- True scale (1:1)
- No duplicate or overlapping paths
- Text converted to outlines
If you’re unsure about setup, send what you have. We can review and advise.
Raised Lettering and Engraving Detail
When to Laser Cut vs CNC Route Acrylic
Laser cutting is best for:
- Intricate shapes
- Thin to mid-thickness sheets
- Engraving and polished edges
CNC routing is better for:
- Thick material
- Deep pockets
- Structural components
Laser Cutting Acrylic FAQs
What is the best acrylic for laser cutting?
Cast acrylic is the best choice because it produces polished edges and bright white engraving contrast.
What thickness is best for laser cutting acrylic?
We prefer .040" (1mm), 1/16", 1/8" and 1/4" sheets. They provide the cleanest cuts and strongest detail retention.
Can you laser cut extruded acrylic?
Yes, but engraving contrast and edge quality are typically lower compared to cast acrylic.
What is a good material for template cutouts?
We like our Solatuf Acrylic Film. At only .030" thin, it cuts quickly and can be used in spray painting template applications or other thin templates.
Does laser cutting leave a polished edge?
Yes. Cast acrylic typically comes off the machine with a smooth, polished edge.
How fast is turnaround?
Many file-ready laser jobs are completed within about 24 hours, depending on complexity and volume.
How fast is turnaround?
Many file-ready laser jobs are completed within about 24 hours, depending on complexity and volume.