Laser Cutting Cardboard: All You Need to Know

Cardboard is a widely used material for packaging. We use it for shipping goods and making cartons and boxes for products. It is a preferred material for the said purpose and is cut in the desired shape and size. But it is a bit delicate, which is why it is difficult to cut using a sharp tool.

In this article, we will discuss cardboard cutting using a laser machine. We will explain how a laser cuts cardboard, why it is an ideal option, and which laser machine you should choose for cardboard cutting. We will clear your doubts and discuss everything you need to know about laser cutting cardboard.

Advantages of Laser Cutting Cardboard? 

Cardboard is made from cellulose fiber or wood pulp. It is similar to paper in origin, but it is a bit thicker. It comes in a wide variety and is commonly classified as heavy paper-based products.

For cutting cardboard, a laser cutting machine is an ideal option. It is because it does not make any physical contact with the material. Laser cutting machines work by using a high-powered laser beam to vaporize the material to cut it into desired shapes and the cutting width (Kerf) is minimal. So, there is no wear and tear at the edges. You get fine and perfect cuts by using a laser cutter.

If you try to cut cardboard using a knife or any other sharp tool, you might end up deforming the material or making uneven cuts. But on the other hand, laser cutting machines are quite precise and accurate. It does not damage or deform the material during the cutting process. Moreover, they are automated by computer, so there is no need for excessive human interference.

By using a laser cutter, it is possible to cut identical pieces. You can process a batch and cut multiple pieces in one go. You can cut intricate designs and patterns without any loss in quality. It can cut thick cardboard up to 20mm or even more without any hassle.

The only thing you need to consider is the safety measures. Cardboards can catch fire quickly and easily, so choosing the right machine settings and maintaining safety measures is a must.

What Type of Cardboard is Used for Laser Cutting?

Cardboards can be classified into various types, depending on the layers, design, and construction. However, we are going to discuss the main types of cardboard used for laser cutting.

Paperboard

Paperboard is just like paper in terms of construction. However, it is considerably thicker and heavier than the common paper we used for printing. It is made by combining several pieces of paper or by compressing paper pulp. It is a dense board, which is why it is strong. You might have seen the covers of magazines and books. All these are made from paperboard.

Corrugated Fiberboard

Corrugated fiberboard is made of three or more layers of paper with one or more corrugated layers in the middle. The corrugated layer is wave-shaped that gives the material its strength and rigidity while maintaing a light weight.

What Thickness Cardboard for Laser Cutting?

Laser machines are quite powerful, they can cut thin and thick cardboard without any hassle. Usually, cardboards have a normal thickness of about 1.7mm, which is used for packing common materials. Thick cardboard boxes have a thickness of around 5-6mm. Many laser owners try to cut several layers of cardboard in one go to save time. But it is not a good idea to stack multiple cardboards together. The smoke traps between these layers, and you may not get the results you need. 

What Laser Cutter Do You Need to Cut Cardboard? 

CO2 Laser Cutters

A CO2 laser cutter is an ideal option for cutting cardboard, paper, and similar materials. The laser beams of a CO2 laser cutter have a wavelength of around 10,600nm. Non-metals can easily absorb these laser beams, including cardboard, rubber, wood, leather, and acrylic. Thus, these lasers can cut cardboard and offer the exceptional results you are looking for.

CO2 laser cutters are quite powerful. By setting these machines at low power, you can cut cardboard with utmost accuracy and finishing. The speed of these laser machines is also exceptional, which saves you a lot of time. Using a CO2 laser cutter, it is possible to cut 15-20mm cardboard without any hassle. A desktop version of these lasers usually costs around $3,500 to $6,000. However, there are industrial CO2 laser cutters, which have a larger working area and higher power. These usually cost more than $10,000.

Diode Laser Cutters

Diode laser cutters are also suitable for cutting cardboard, paper, and similar materials. These lasers are also the first option for many beginners because they are easy to use as well as affordable. The cost of the laser can be $700 to $1,500, depending on the optical power and features.

How to Laser Cut Cardboard? 

Here are some general steps you can follow to cut cardboard using a laser cutting machine.

Step 1: Set up the laser machine. Connect the machine to the computer and open the software. Before cutting cardboard, ensure all the safety measures. There should be a fire extinguisher nearby and turn on the air assist and exhaust system.

Step 2: You need to import the design to the software. You can design your boxes, toys, or whatever you want on Adobe Illustrator, CorelDRAW, Inkscape, or any other suitable design tool you use. Design the laser-cut files according to your requirements. You can also get free or paid files from various websites, such as 3Axis and Etsy. Once the laser-cut file is ready, import it to the laser software.

Step 3: In the working area, you need to place the cardboard sheet. Secure the sheet using magnets, paper tape, or whatever you use. The cardboard can change its position due to heavy blow of air assist, so make sure to secure it. Adjust the focus of the laser machine on the cardboard. Now, place the laser head at the starting position of the cutting.

Step 4: Set the laser parameters, such as power, speed, and number of passes. For optimal results, you should do a power-speed test on a spare material. It will give you a complete idea of what parameters are suitable and what not to use. If the power of the CO2 laser is 55W, you can set the power to 100% and speed at 50% for 3.5mm corrugated paper. Adjust the settings according to your machines and the thickness of the cardboard.

Make sure to turn on the air assist. It will help in cutting cardboard and removing the smoke from the object.

Step 5: You can start cutting cardboard. Complete framing to ensure the positioning of the laser head. Start the cutting process. After cutting, take out the material from the working area. 

Best Cardboard Laser Cutter

xTool P2 is a powerful, smart, and versatile CO2 laser cutting machine that is ideal for small businesses, DIY, art, and other purposes. It has an optical power of 55W, which can cut thick materials in no time, so cutting cardboard won’t be an issue. It can offer exceptional cuts at an incredible speed of up to 250mm/s.

The laser machine is equipped with two cameras. These take the whole picture of the working area and give you a live preview. It makes the positioning of the materials a lot easier. These cameras make the machine intelligent. It can process a batch of objects at a time and engrave curved surfaces.

The notable feature of the machine is the passthrough. It feeds the material from one end and delivers from the other. With that being said, you can cut and process large materials without any restriction on the length. You can also install the automatic feeder and cut large cardboard up to 118 inches long.

The machine contains a built-in exhaust system. It removes the smoke produced during the cutting of cardboard and other materials. It ensures the cutting results are more than perfect without any discoloration. You can also attach the air purifier to the machine and use it even inside your kitchen without any worries.

It is an ideal machine for cutting as well as engraving. You can engrave 3D objects with clean and up-to-the-mark engraving. The machine creates a 3D model of the object on its own and adjusts the focus of the laser accordingly. It can also engrave spherical and cylindrical objects, such as rings, tumblers, pens, and balls, using the rotary attachment RA2 Pro.

The machine is equipped with tons of safety features. The most important one is fire safety. You can attach the fire safety kit to the machine to detect and quench the fire automatically without harming anything. It also has a warning system, emergency stop button, automatic lock, hydraulic support, etc.

It is an incredible laser cutter for cardboard, wood, acrylic, leather, rubber, plywood, and various other materials. It is a versatile and powerful machine that does the job at a commendable speed. You can cut cardboard with perfection, and it will offer you optimal accuracy, clean cuts, and quick results without any hassle.

Cardboard Laser Cutting Safety Considerations

Cardboard is made from paper, wood pulp, residuals, and similar materials. It can catch fire easily, so there are extra safety measures that you should consider while laser cutting cardboard.

• Make sure to turn on the air assist. It is a must-have for laser cutting cardboard. It not only assists in cutting but also prevents fire through its powerful air blow. It removes the smoke from the object and lowers the temperature.
• The laser machine should have a fire alarm and safety features. It is better to connect the fire safety kit to prevent any accidents.
• You can keep a fire extinguisher near the machine to deal with fire.
• Never leave the machine unattended when it is working.

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