Laser Cutting Cardboard: All You Need to Know
Cardboard is a widely used material for packaging. It's cut in the desired shapes and sizes to make cartons and other products. Laser machines are an ideal option for cutting cardboard.
In this article, we will discuss laser cutting cardabord. We will explain how it works, why it is an ideal option, and which laser machine you should choose for cardboard cutting.
In This Article
- How Laser Cutting Cardboard Works?
- What Type of Cardboard is Used for Laser Cutting?
- What Thickness Cardboard for Laser Cutting?
- What Laser Cutter Do You Need to Cut Cardboard?
- How to Laser Cut Cardboard?
- Best Cardboard Laser Cutter
- Cardboard Laser Cutting Safety Considerations
How Laser Cutting Cardboard Works?
Laser cutting machines use a high-powered laser beam to cut materials. This beam is focused to create a tiny point of intense heat. This concentrated heat causes the cardboard at the point of contact to vaporize, which removes a tiny portion of the material, leaving behind a clean-cut edge.
The laser cutting process is guided by software. It dictates the exact cutting path the laser beam takes, allowing for precise and intricate designs to be cut into the cardboard.
Laser cutters not only cut materials, but they can also engrave designs onto the cardboard surface by adjusting the laser power settings. This adds another layer of creative possibility for your laser-cut cardboard projects.
Unlike traditional cutting methods that use blades or dies, a laser cutter doesn't physically touch the cardboard. This minimizes wear and tear on the cardboard, resulting in cleaner cuts and smoother edges.
The laser beam itself has a small width, which translates to a minimal kerf (the width of the cut itself) in the cardboard. This is a major advantage compared to mechanical cutting tools.
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.
laser-cut corrugated cardboard pumpkin lantern
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 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 laser cutting smoke will trap 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. 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. There are also 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 more affordable. The cost of the laser can be $700 to $2,500, 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: 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 cutter software.
Step 2: Place the cardboard sheet in the working area. Secure the sheet using magnets or paper tape. The cardboard can change its position due to heavy blow of air assist, so make sure to secure it.
Step 3: Place the cutting design on the cardboard. Laser cutters are often equipped with a camera for working area preview or provide other positioning methods. Adjust the focus of the laser head on the cardboard.
Step 4: Set the laser cutting parameters, such as power, speed, and number of passes. For optimal results, you should do a power-speed test on a spare material. If you use a 55W CO2 laser, you can set the power to 100% and speed at 50% for 3.5mm corrugated cardboard. 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: Complete framing to ensure the positioning of the design. Start the cutting process.
Best Cardboard Laser Cutter
xTool S1 Diode Laser Cutter
xTool S1, with its powerful 40W diode laser, is capable of cutting through much thicker materials like wood in a single pass. Cardboard, being significantly thinner, will be efficiently and cleanly cut by the S1. Its versatility extends beyond cardboard. It can also cut and engrave a variety of materials including wood, paper, leather, fabric, and even opaque acrylic.
With a bed size of 23.93 by 15.16 inches, the interior offers ample space for most cardboard projects. And for those extra-large projects, the AutoPassthrough™ Technology allows you to feed material through the machine for continuous cutting.
While some laser cutters use cameras for design mapping, the S1 features a user-friendly Pin-point Positioning™ System. This allows you to define the cutting or engraving area simply by marking a few points on the software, making it a breeze to use even for beginners.
Safety is a priority with the xTool S1. As a Class 1 Laser Product, it's designed for safe home use with an enclosed casing that keeps laser beams and fumes contained. There's no need for goggles thanks to the laser filtering lid, and the machine also features a lid-open safety stop button and a 5-direction flame alert system for added peace of mind.
xTool P2 CO2 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 camer. These take the whole picture of the working area and give you a live preview. It makes the positioning of the designs a lot easier. They also allow the machine process a batch of objects at a time.
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 cardboard up to 118 inches in length.
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. The machine creates a 3D model of the object's contour and adjusts the focus of the laser accordingly, allowing it to engrave curved surfaces. 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. It also has a warning system, emergency stop button, automatic lock, etc.
It is an incredible laser cutter for cardboard, wood, acrylic, leather, rubber, plywood, and various other materials.
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 accessories 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.
- Never leave the machine unattended when it is working.
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