Cutting acrylic instead of milling
Why the laser delivers the better finish
Acrylic glass - often known by trade names such as Plexiglas® or Perspex® - is a popular material in advertising technology, model making, store fitting and interior design. The material impresses with its high transparency, UV resistance and elegant appearance. However, precision and quality are particularly important when it comes to cutting - because unclean edges, cracks or stresses not only impair the aesthetics, but also the functionality.
Traditionally, acrylic is often milled. However, more and more companies are switching to laser cutting acrylic - with convincing advantages. In particular, the smooth cutting edge with the laser is a decisive criterion that speaks in favor of modern laser technology.
The advantages of laser cutting acrylic
The difference between milling and laser cutting lies not only in the processing method, but also in the quality of the result. While acrylic milling uses a rotating tool to cut the material, the laser works without contact and with pinpoint accuracy - opening up completely new possibilities.
Precision and accuracy
A major advantage of laser cutting is the high precision and accuracy achieved with this method. The laser beam is extremely fine and makes it possible to cut even the most complicated contours and intricate details cleanly and precisely. Milling tools quickly reach their physical limits here, especially with very thin material or small internal cut-outs. Mechanical forces are at work during milling, which can lead to undesirable vibrations and inaccuracies. The laser works without contact and is therefore vibration-free.
Smooth cutting edges
A particularly important aspect when cutting acrylic is the quality of the cut edges. Laser cutting produces smooth, clear and polished cut edges that often require no further finishing. This is because the laser beam melts and vaporizes the acrylic material, resulting in a clean cut and a shiny surface. In contrast, milling often leaves matt, slightly rough and jagged edges that have to be subsequently sanded or polished to achieve an acceptable finish. This costs time, material and increases production costs.
Flexibility in material thickness
Laser cutting offers a high degree of flexibility in terms of material thickness. Whether thin or thick acrylic - the laser can cut almost any material thickness effortlessly and precisely. When milling, however, different material thicknesses can lead to problems, especially with very thin or very thick materials, as the cutter often has to be adjusted and does not always work evenly.
Less material wastage
Another advantage of laser cutting is that less material is wasted. As the laser beam is very narrow, only a minimal amount of material is removed. This is particularly advantageous with expensive materials such as acrylic, as it reduces costs and enables more efficient use of the material. Milling, on the other hand, removes and wastes comparatively more material, which can drive up production costs.
Efficient workflow without tool wear
When milling, the tool wears out over time - the edge quality suffers and set-up times increase. Lasers, on the other hand, are wear-free. Designs are transferred directly from the software, without changing cutters or clamps. This saves time, reduces costs and enables a smooth production process - even with changing orders.
Speed and efficiency
Laser cutting is generally faster and more efficient than milling. As the laser beam focuses high energies on a small point, cuts can be made in a short time. This leads to higher productivity and shorter processing times. Machining times are often longer when milling, as the tool has to be moved mechanically through the material, requiring complex settings and adjustments.
Surface engraving
An additional advantage of the laser over the router is the ability to create precise surface engravings. The laser can not only cut, but also engrave the acrylic with a high level of detail and consistency. These engravings open up numerous design possibilities, from the production of personalized products to the insertion of texts and logos to complex patterns and designs. In contrast, router engravings are often less precise and require additional tools and settings.
Comparison of acrylic lasering and acrylic milling
Processing quality
A comparison of the processing quality of lasers and milling clearly shows that laser cutting has the edge. Laser-cut acrylic parts generally have a higher surface quality, as the laser beam cuts the material precisely and cleanly. Milling, on the other hand, can result in irregularities and roughness that impair the aesthetics and functionality of the parts.
Processing speed
In terms of processing speed, laser cutting is superior to milling. The laser beam can cut through the acrylic material quickly and efficiently, resulting in shorter processing times. This is particularly advantageous for large series production or urgent orders where time is a critical factor.
Post-processing
Another important aspect is post-processing. Laser-cut acrylic parts often require no additional post-processing as the cut edges are smooth and polished. Milling, on the other hand, often requires post-processing to smooth the cut edges and achieve the desired surface quality. This means additional time and effort, which can be avoided if lasers are used.
Typical applications for lasered acrylic parts
- Advertising technology: logos, letters, 3D lettering
- Model making: Precisely cut plates and components
- Medical technology: housings, holders and transparent covers
- Furniture & interiors: decorative elements, light covers, design objects
- Store fitting: POS displays, shelf supports, protective screens
The combination of aesthetics, flexibility and precision makes acrylic laser cutting the preferred solution in many areas of industrial and craft production.
In summary, it can be said that laser cutting acrylic offers numerous advantages compared to milling. The precision, smooth cut edges, flexibility in material thickness, reduced material waste, speed and efficiency make lasers the preferred method. Added to this is the ability to create high-quality surface engravings, which open up further creative and design options.
So if you are looking for high-quality and cost-effective processing of acrylic, you should opt for laser cutting. The results speak for themselves and show that the laser delivers the better finish.
FAQ: Frequently asked questions about laser cutting acrylic glass
What thickness can be processed with acrylic lasers?
CO₂ lasers are ideal for acrylic sheets with thicknesses from 1 mm to approx. 20 mm. Depending on the laser power and material type, thicker sheets can also be processed, but with the speed adjusted accordingly.
Does laser cutting cause stress cracks or beveled edges?
No - professional laser cutting does not cause stress cracks. Precisely adjusted power and suitable extraction also ensure that the cut edges remain clear and free of smoke.
Is laser cutting faster than milling?
Yes - laser cutting is significantly more efficient, especially for intricate or complex shapes, as no tool changes or clamping systems are required. There is also no need for manual reworking of the cut edges.
Can colored or satin acrylic also be laser cut?
Yes - colored, satin or opaque acrylic types can be cut just as precisely as transparent material. The settings are individually adjusted to the respective type.
Is a laser system also worthwhile for small series or one-off productions?
Definitely - thanks to the digital workflow and the elimination of set-up times, laser technology is ideal for customized individual pieces as well as for recurring series production.
