Online custom laser cutting service, for startups & enterprises.

Prototyping & production laser cutting, using 450+ metals, plastics, composites, rubbers, foams & woods.

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Custom parts delivered same day.

Our laser cutting capabilities

To ensure that we can provide laser-cut parts to the highest degree of quality, we provide different laser-cutting technologies, including CO2 and fiber, and each technology is specially matched to different materials to provide consistent results.

Regardless of the material, quantity, or size, all parts have a dimensional accuracy of ±0.13mm, a minimum feature size of 1x1mm, and a minimum laser kerf of 0mm. The maximum material thickness that our laser cutting stations can handle is 25.4mm (before the laser kerf becomes too large), the maximum dimension for parts made from any sheet material is 3000mm x 1500mm.

Our CO2 laser cutting capabilities

Min lead time

Same day

Max laser power

120W

Dimensional accuracy

±0.13mm

Laser kerf

0 - 0.2mm

Material thickness

0.1 - 19.1mm

Max part size

3000 x 1500 x 12.7mm

Min part size

6 x 6 x 0.1mm

Min feature size

1 x 1mm

Part quantity

1 - 100,000

Shipping within USA

Free

Guaranteed tolerances

Get custom quote

Our fiber laser cutting capabilities

Min lead time

Same day

Max laser power

3kW

Dimensional accuracy

±0.13mm

Laser kerf

0 - 0.1mm

Material thickness

0.4 - 25.4mm

Max part size

3000 x 1500 x 25.4mm

Min part size

15 x 15 x 0.4mm

Min feature size

1x material thickness (min 1mm)

Part quantity

1 - 100,000

Shipping within USA

Free

Guaranteed tolerances

Get custom quote

Sheet metal fabrication service

See our capabilities here

Custom parts delivered same day.

What is laser cutting?

Laser cutting is a subtractive manufacturing process that uses a laser beam to cut parts out of sheet material. However, laser beams don’t cut or melt, but instead, use their intense laser energy to vaporize material which prevents material from catching fire or degrading. Laser cutting machines are numerically controlled by computers (hence, making them CNCs), and this allows for laser cutters to produce any 2D (changing the commands will change the shape), and also makes laser cutters capable of providing a great degree of precision over many thousands of parts.

Due to the many advantages presented by laser cutters, they are extremely popular amongst engineers, especially for prototyping and low-volume production runs. Parts that would otherwise take hours to make on standard CNC mills can be done so on a laser cutter at a fraction of the cost in a fraction of the time.

Laser Cutting Materials

To help engineers choose the right material, we have over 450+ materials in stock, all of which are suitable for laser cutting and provide for precision capabilities. Our engineered materials means that the internal structure, consistency, and density is uniform, which creates parts whose exact weight, tensile strength, and center of mass is well defined. At the same time, engineered materials guarantee precision among different parts, even if they are manufactured at different times.

Of course, there will be applications that call upon very specific materials, and we accept custom material requests. If you require a custom material, let us know what the material is and where it can be purchased from so we can provide an accurate quote, but remember, we can only cut laser-safe materials.

Custom parts delivered same day.

How software-driven manufacturing helps your laser cutting

Manufacturing can be an extremely complex and tedious process; parts have to be designed correctly, those parts must be manufacturable, manufacturing data needs to be generated around that part, and those responsible for the parts manufacture need to understand the requirements of that part. Traditionally, this entire process would take many hours of valuable engineering time, and the slightest bit of miscommunication can result in a failed part.

Our software-driven manufacturing services help to simplify the laser cutting manufacturing service by separating engineers from the manufacturing and providing a set of online tools that provide instant quoting depending on the chosen material, part complexity, and part quantity. Our software tools mean that within minutes of uploading your design, you can choose your material, enter your order quantity, pay, and have your part put immediately into production.

Another major advantage to our software-driven manufacturing service is that all our other services, including finishing, are combined into a single online tool, allowing you to keep all part manufacturing under one roof. This significantly reduces the complexity of manufacturing while simultaneously protecting intellectual property.

But the most important feature of our software-driven laser cutting service is that it allows you to scale your project from prototype to production with a single click. Our laser cutting services do not distinguish between prototypes and market-ready parts, meaning that even single prototypes perfectly represent what you would receive when ordering parts in the thousands.

How much does laser cutting cost?

Laser cutting prices depend on numerous factors, including the material used by a part, the part size, the complexity of the part, and additional finishes.

When considering the machining costs, the longer it takes to cut out a part, the more expensive it will be. Simple shapes, such as rectangles and circles, are very quick to cut, which makes them cheaper to manufacture (as opposed to intricate parts with many cut-outs). Large graphical areas that use engraving take a long time to produce, making engraved parts more expensive. However, compared to other manufacturing methods (such as CNC milling), laser cutting is by far one of the most economical options available to engineers.

In addition to the low operating costs, laser cutters also lack tooling and unique customisation, meaning that they are significantly cheaper and easier to operate compared to CNC mills.

To demonstrate just how cost-effective laser cutting is, you can upload your part to our online software-driven manufacturing service, select your material, and see an instant price for that part in different quantities.

Custom parts delivered same day.

High-speed, precision laser cutting, guaranteed to last

When it comes to manufacturing, quality is essential; parts that cannot be made to a high degree of accuracy and precision are unreliable. However, it is also essential that parts are manufactured at speed to ensure that parts are economically viable. Our years of experience in the laser cutting field have enabled us to find the perfect balance between quality and speed, ensuring that our software-driven services provide customers with the parts they need at excellent prices.

To demonstrate our confidence in the parts we produce, all parts come with a 365-day guarantee, no matter the size of the order, the material is chosen, or the complexity of the part. This guarantee provides engineers a degree of confidence in the reliability of their parts, not just from the first order, but for every part in every order.

What parts can be made using laser cutters?

Laser cutting is excellent for creating faceplates such as those used on industrial equipment, control panels, user interfaces, musical instrument, and medical devices. This is especially true for the electronics industry, where almost all electronic devices are housed in some kind of enclosure.

Laser cutting is also ideal for creating small mechanical parts out of metal and plastic. For example, miniaturized gears used in complex mechanical devices can take advantage of the low-cost, high-precision capabilities of laser cutting.

Wood laser cutting is ideal for use in artistic applications where aesthetics are important. The high temperature of laser cutting result in cut edges having a charred appearance, and this can create strong contrasts in designs which are hugely popular with wood boxes, device enclosures, and pattern engravings. Metal laser cutting can be used to manufacture brackets and fittings, and the combination of our laser cutting service with our metal bending and finishing services allows for the creation of market-ready 3D parts.

Our laser-cut cardstock and textiles are ideal for fashion and crafts, which include product packaging, material insets, cards, promotional materials, and decals. Some textiles, such as felt, can even be used in some engineering applications, including seals and O-rings.

Faceplates for enclosures

Any electronic device that has user interfaces, connector ports, or cut outs will require an enclosure that has a flat face, and while this can be integrated into the case design, it is often easier to create a separate faceplate that is inserted into the enclosure. Making faceplates can be done with numerous different manufacturing techniques, but laser cutting offers the most economical option for prototypes and low volumes. The ability to provide clean cuts creates faceplates that are market-ready immediately after cutting, and the ability to also engrave graphics and text can remove the need for additional processing steps (such as direct printing and image transfers). Finally, laser-cut faceplates are extremely professional looking, something which can transform prototype products using off-the-shelf enclosures.

Artistic and luxury Products

Wood laser cutting is ideal for use in artistic applications where aesthetics are important. The high temperature of laser cutting result in cut edges having a charred appearance, and this can create strong contrasts in designs which are hugely popular with wood boxes, device enclosures, and pattern engravings. This is commonly seen in the gifts industry as well as in luxury items that want to give the impression of a hand-made product. Furthermore, wood is an excellent for laser engraving as the charred cut lines are extremely easy to see. Finally, wood is easy to machine and work with, making it an excellent material choice when creating basic prototypes of new products where engineers may need to make adjustments.

Mechanical insets

Consumer electronic products that require a metal separator along the perimeter of the enclosure, or a piece of metal shielding to reduce EMI can also take advantage of laser cutting. While CNC machining can be used to create such parts, the strong mechanical forces exerted on thin sheets during machining can introduce warpage, and the long time taken by CNCs makes it highly expensive. Laser cutting, however, can make quick work of thin sheets of metal such as stainless steel and aluminum, and the quality of laser-cut parts allows for parts to be immediately used in products without the need for further processing.

Why you can trust Ponoko

Ponoko has years of experience in the laser cutting and engraving industries, having served over 33,000 customers and manufacturing over 2 million parts. Our 99.7% precision part quality record demonstrates our ability to manufacture parts reliably, and our 365-day guarantee ensures that all parts ordered will meet all requirements. No matter whether it’s a prototype or a market-ready production piece, every single part we manufacture is treated equally to the same exact high-quality engineering standards. As such, you can trust our laser cutting services for all parts, no matter the order.

Laser cutting FAQ

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How fast is laser cutting?

Compared to other manufacturing techniques, laser cutting is one of the fastest options for engineers. The speed of a laser cutter depends on numerous factors including the thickness of the part, the complexity of the shape, the total length of cut needed, and the material being cut, but basic shapes and outlines can be cut in seconds. But to truly appreciate the speed of laser cutters, other manufacturing processes need to be considered. 3D printing is a manufacturing method that is great for complex 3D structures (something that laser cutting cannot do), but the length of time taken by 3D printers only makes them suitable for individual prototypes. By the time a 3D printer has printed its first layer, a laser cutter would have easily cut out multiple parts from a sheet of material. CNC milling is an excellent option for precision work, but the use of a rotating milling bit to remove material from a workpiece usually requires multiple passes over that piece at varying depths. Furthermore, CNCs require the workpiece to be clamped down due to the mechanical force of the cutting bit, and just like 3D printers, a laser cutter could easily produce multiple parts in the time taken for a single pass of a CNC. Injection molding is one of the few manufacturing processes that can compete against laser cutting for time, but while injection molding is faster, it is also extremely expensive to set up due to the need for molds. As such, injection molding is often reserved for large-scale production where quantities exceed 10,000. Our use of laser cutting technologies allows us to manufacture parts to a great degree of precision while offering turnaround times not available from other manufacturing processes. A rush order placed before 11 AM (and a quantity below approximately 100 custom parts) is not only fabricated that same day but also shipped that same day. Customers in the Bay Area can receive their parts the same day meaning that a design submitted in the morning will be delivered to your door before that very evening.
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What makes laser cutting advantageous?

There are four primary advantages that, when compared to other manufacturing methods, laser cutting presents, which is why laser cutting is so popular. First, laser cutting is extremely fast compared to other popular methods such as CNCs and 3D printers meaning that engineers spend less time waiting for parts to be fabricated (and thus can accelerate project development). Second, the lack of tooling means that a laser cutter can be cheaper and easier to maintain compared to CNCs which have expendable parts (this also helps to accelerate manufacturing times by removing the need for tool changes). Third, the lack of mechanical forces on the workpiece being cut means that parts do not require tabs or breakouts to hold them in place. As such, parts can be neatly cut out of a sheet of material and require no additional processing, again, saving time. Fourth, the dry nature of laser beams also allows for numerous materials to be cut including paper, cardboard, wood, and felt (something which cannot be done using a water jet). Finally, laser cutters can be controlled using numeric control systems meaning that any shape can be cut. Not only does this allow for prototypes to be quickly fabricated, but it also allows for parts to be manufactured at scale with no need to adjust machinery or design files. Once a design is ready for mass production, a laser cutter will treat that design in the exact same way whether one part or one thousand are being made. Our use of laser cutting technologies helps to bring the advantages of laser cutting to our customers through high quality and high precision parts in extremely short timeframes. The use of our online software-powered manufacturing service enables engineers to upload, quote and order parts in minutes, and our ability to manufacture and ship products same day helps engineers to decrease the time between design iterations and thus accelerate the completion of projects.
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What laser technologies exist?

When it comes to industrial laser technologies and laser cutters there are three main contenders: LED, CO2 and optical fiber.LED lasers are by far the cheapest laser cutter technology on the market and are commonly found in DIY desktop laser cutters. However, their low energies (typically less than 10W) and price mean that they are also the weakest and are mostly used to cut and perform laser engraving on paper and wood (even then, wood is difficult to cut with an LED laser beam).CO2 lasers utilize a tube of CO2 gas that is then excited with an energy source to produce a uniform beam of infrared light. CO2 lasers are significantly more powerful than LEDs and as such can be used for harder materials such as thick wood and metal (depending on the energy of the laser and thickness of the material). But due to the laws of economics, CO2 lasers are more expensive than LED lasers with industrial units starting at around $10,000. As such, they are only economical to own and operate if being utilized on a daily basis.Optical fiber lasers are the most powerful industrial laser cutting technology that utilizes rare-earth elements in a fiber optic cable. The use of fiber allows for light energy to be trapped (as a result of total internal reflection), and this aids in generating a powerful focused laser beam. As such, fiber lasers are used in applications involving the toughest and thickest materials. But, just like CO2 lasers, the increased power and capabilities of fiber lasers make them some of the most expensive with prices typically exceeding $100,000 and are only economical for manufacturers using them on an hourly basis.Here at Ponoko we house a wide range of laser cutting technologies including both CO2 and fiber laser systems all calibrated to ensure that all parts manufactured by us meet our strict standards. Our carefully selected range of materials has also been paired with different laser systems to ensure the most efficient cutting, and our years of experience as a laser cutting company ensure that all machines operate flawlessly. Considering that we have manufactured over 2 million parts, it goes without saying that when it comes to laser cutting, we are a cut above the rest.
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What software can I use to create laser cut parts?

Any design software that can output files compatible with our online software service can be used (we accept 3D STEP, 2D DXF, SVG, EPS and Ai files). Like with any manufacturing process, the software used to design a product never interacts with the machinery, and most manufacturers will convert submitted files into their own specific formats.In the case of laser cutters, design files are converted into g-code that dictate where the laser head is positioned as well as the energy output of the beam. For example, areas being engraved instruct the laser head to reduce power while areas being cut increase this power.For those looking for a suitable design software package, engineers have numerous options available to them with some being paid for and others being free. FreeCAD is one option that designers can use and is ideal for those looking for an open-source environment. It is able to export common file formats, and its ability to design both 2D and 3D parts makes it ideal for those looking to expand their use of CAD.For those looking for a more engineer-oriented design software suite, Alibre makes a good choice as it is specifically designed with engineering projects in mind. Individual parts can be designed, combined, and then mechanically simulated. From there, parts can be outlined and exported for use with Ponoko laser cutting services. Other design software options available to engineers also include AutoDesk which is massively popular within the CAD community and SolidWorks which is able to create complex engineering projects just like Alibre. Then we have online CAD tools like Autodesk's Fusion 360 and PTC's OnShape.
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What files do laser cutters read?

Laser cutters themselves do not directly read design files, but instead, read a numeric language called g-code. G-code files are plaintext and usually have the extension .nc or .ngc, and while g-code is mostly standardized, some interpreters will have unique code instructions (for example, Mach3 and LinuxCNC have different codes for probing and storing variables). This use of non-standard g-code means that laser cutting companies (such as Ponoko) will never accept g-code from customers, and instead use internal software solutions to generate this code.Ponoko supports a wide range of different file formats including STEP, DXF, EPS, Ai, and SVG, and these file formats are generally supported by CAD packages. While the software package used to create these files is not important, it is recommended that it is able to work with vector graphics as vector designs can be scaled without losing quality. Additionally, g-code used by laser cutters is also based on vectors, and this means that vector designs are far easier to produce compared to raster images.As a laser-cut part can have both cuts and engravings on the same part, it is essential that designs submitted to us consist of two layers in different colors. For example, red lines can be used to represent cuts while blue lines represent engravings. When submitting parts to be cut our online software service automatically detects this and will ask you what each color represents.
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Should I use vector or raster graphics with laser cutters?

Designs submitted to Ponoko can either be in vector or raster format, and it is important for engineers to recognise the difference between the two in order to achieve the best result possible.Vector designs are those that describe the shape of a pattern with the use of geometric lines and curves often indicating a start co-ordinate, an end co-ordinate, and additional details to the line such as rate of curvature. As such, vector designs are more akin to a set of mathematic equations that are executed to generate a shape.Raster designs, however, split up a design into an array of pixels that indicate the presence of material. The quality of a raster design highly depends on the size of each pixel, and designs that use large pixel sizes will suffer from blurred edges and low-resolution images. However, using a large resolution and small pixel size can see extremely large design file sizes as well as taking longer to cut using a laser cutter.As such, vector files are excellent for describing the outline of a shape as they naturally translate to machine motion, while raster designs are ideal for engraving complex patterns such as images, logos, and text.
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How expensive is laser cutting?

Laser cutting offers engineers one of the most economic solutions by far, due to the low operating costs of laser cutters, the speed at which they can cut, the ability to scale with ease, and the ability to cut any 2D shape without the need for machine-specific settings. First, laser cutters use a beam of light to remove material meaning that there are no expendable tools involved (such as drills and blades). While there are optical components to a laser cutter, these rarely require replacement especially if the laser cutter is well maintained. As such, the only major cost in operating a laser cutter is the electricity needed to generate the laser beam. The lack of molds commonly found in other manufacturing methods also removes the need for custom tooling or part-specific equipment. A laser cutter can accept any design file and start cutting without any changes made to the laser cutter itself. While plastic injection molding is cheaper than laser cutting, this is only the case for large order quantities in excess of ten thousand. Even then, plastic injection molding doesn’t support sudden design changes as new molds are required. As a laser cutting company, we are committed to offering our customers an excellent balance between cost, quality, and speed. Our online software-powered service allows for designs to be uploaded and quoted without any input from us which allows engineering teams to spend more time focusing on material selection and part design.
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Can 3D shapes be cut using a laser cutter?

While laser cutters are only capable of cutting 2D shapes, 3D parts can be fabricated from multiple 2D parts using numerous techniques.For example, stacking slices a 3D shape into multiple layers that are stacked together with each layer being a planar shape. Stacking is ideal for non-complex 3D shapes such as enclosures that have little variation on the sides of their faces. Furthermore, stacking allows for material variation between each layer, and this can be used to create unique patterns and designs, but the use of stacking can be expensive if layers are thin and waste large portions of material.Another technique for creating 3D structures is the use of bends whereby a 3D shape is exploded into a 2D shape that is bent into shape (similar to origami). However, while this method is useful for boxed designs and keeping costs low, it is not suitable for intricate designs with complex features.Joints can also be laser cut into most materials and have been a popular method for connecting parts together for centuries (if done correctly, joints can hold a structure together without needing any screws or glue as is in many Japanese houses and wooden castles). But while joints are an excellent method for holding parts together, they require extreme care as joints that are not designed perfectly can be loose.Recognising the numerous challenges faced by engineers, we offer a range of additional finishing services to our laser-cut parts including metal bending. Designs that specify bend lines can transform a flat 2D shape into a 3D structure, and is ideal for parts such as brackets, fixtures, and enclosures. This is especially advantageous for engineers looking to minimize the number of manufacturing steps on their part as well as removing the need for customers to have access to cut metal bending services.
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What precision does laser cutting offer?

The consistency of laser beams and the use of stepper motors allows for laser cutters to be used to make precise cuts. At Ponoko, our precision is within 0.13mm tolerances. Lasers are so accurate, they are frequently used to actively trim precision capacitors and resistors whereby material is removed until the desired electrical characteristic is achieved. When compared to other manufacturing technologies, laser cutting provides the best trade-off between precision and speed. For example, 3D printing is notorious for poor dimensional accuracy when printing with plastic materials such as PLA and ABS, while printing metal powders causes challenges with accuracy as heating the part causes shrinkage. CNC milling is a manufacturing process that can achieve better precision than laser cutting, but the long length of time taken for each pass means that it’s only applicable in applications where precision is essential (i.e. fitting pistons into an engine block). High-powered laser beams can struggle to form small cutting diameters, while low-powered beams will struggle to cut outright. This means that while laser cutters can offer excellent dimensional accuracies, they are not ideal for creating tiny features with narrow cutting widths and complex parts close together. To ensure consistency across all parts and materials, we have created a list of capabilities that are always guaranteed regardless of what material you choose or the size of the part. For example, the dimensional accuracy on all parts is ±0.13mm meaning that no matter the size of your part, its size will always be within ±0.13mm of the stated dimension. The smallest parts that we can cut are 6x6mm in size due to the use of grated beds (this means that parts smaller than this would fall through holes in the laser bed). Complex features on parts have a minimum size of 1x1mm otherwise the extreme heat of the laser may cause warping and disfigurement.
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What is a laser kerf and should I be worried about it?

A laser kerf is when the laser burns away a portion of material when it cuts through. When getting a part laser cut, it is very easy to forget the importance of laser kerf and how it is affected by material thickness.In an ideal world, a laser beam would never diverge meaning that the width of the beam always remains the same. In reality, laser beams diverge due to imperfections and the unpredictable nature of materials meaning that the width of a laser beam widens as it leaves the laser source.As laser cutters also experience this divergence, they experience a phenomenon called laser kerf which is the widening of the cutting width that increases with cutting depth. For example, the very top surface of a material being cut with a laser will experience negligible laser kerf, but the backside of the material will have a wider cut line due to beam divergence. If viewed on the side, the cut would have a trapezoid shape with the top side being the narrowest and the underside the widest.For thin parts (less than 1mm), kerf can often be ignored as laser kerf is proportional to the depth of the cut (meaning that thin parts exhibit little kerf). Thicker parts, however, may have a more notable kerf that can affect the performance of the part if not considered. For example, a face plate for an enclosure will have shorter edges on the backside meaning that the plate will not sit flush with the edges of the enclosure.
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What challenges do laser cutting machines face?

There are typically four challenges associated with laser cutting, namely, the requirement of "laser safe" materials, inability to cut 3D shapes, beam divergence (or laser kerf), and setup / maintenance of the machines themselves.With its ability to cut parts extremely fast, require no specialized tooling, and do so at scale, it would seem that laser cutting is the ultimate solution in manufacturing. But for all its advantages, there are several challenges faced with laser cutting that engineers should consider when designing parts.The first consideration is that laser cutters can only cut materials that are deemed “laser safe”. A laser safe material is one that produces consistent results when cutting the same part, doesn’t damage the laser cutter, and doesn’t harm the environment. For example, engineered woods such as MDF are excellent for cutting with a laser cutter, but PVC is problematic as it releases chlorine when vaporized. As such, a project requiring materials that are not laser-safe cannot use laser cutting.The second challenge associated with laser cutters is that they are only able to cut 2D shapes. While this is perfectly acceptable for 2D parts, trying to manufacture 3D parts on a laser cutter is no small feat. Of course, numerous techniques can be deployed such as bends, living hinges, and joints, but none of these produces a native 3D part (whereas CNC milling and plastic injection molding can).The third challenge with laser cutters is that they experience beam divergence called laser kerf. Simply put, the further away a target is from a laser, the wider the cutting beam becomes, and this cause the cutting width to increase with distance. As such, thick materials being cut on a laser cutter can have a tapered underside which can cause issues if flat edges are required.The fourth challenge is that laser cutters themselves are extremely difficult to set up and maintain. This difficulty arises from the nature of lasers requiring careful beam alignment, the need to match materials to specific cutters, and the general challenges involved with CNC machines (motor turning etc.).Fortunately, Ponoko being a laser cutting company has years of experience in this field meaning that engineers can take full advantage of laser cutting without having to worry about machine operation or maintenance. With no need for investment in machinery or training, customers can submit parts onto our online quote system, receive a price, and place an order for immediate manufacturing (and same day delivery).
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What materials can be laser cut?

Many materials can be cut with a laser including metal, plastic, wood, organics, and more, but contrary to popular belief, lasers don't melt the part they are cutting but instead vaporize the material. It is this vaporization that allows laser cutters to work with combustible materials such as wood and paper without setting them alight. Types of metal that are popular with laser cutters include aluminum, brass, and steel as they work well with fiber lasers, but metal such as copper can be challenging as their reflective nature can damage optical components in the laser cutter. Common plastics used with laser cutters include acrylic and Delrin thanks to the clean edge left by the laser cutter, the ease of cutting, and their durability. Popular organics used with laser cutters include paper, cardboard, wood, and felt. Thicker and thin materials can introduce unique challenges. Even though various materials can be used with laser cutters, not all can as some can be toxic while others can damage the laser cutter itself. As such, engineers are often tasked with finding suitable material stock that is laser safe, and this can use up valuable time. To help engineering teams, Ponoko has a curated range of laser-safe materials all available through our online part ordering app. Our range of materials include engineered metal, wood, plastic, and more, our materials have carefully controlled characteristics such as tensile strength, density, and electrical conductivity. This is especially useful for engineers designing parts for applications with tight controls such as medical, automotive, and aerospace. But if there is a very particular material you need cut, then we can do that too! Just send us an inquiry stating the need for a custom material and our engineers will help arrange the project, or select “Custom Material” when choosing a material from our online materials catalog.
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Are there materials that cannot be laser cut?

Yes, it's true that not all materials can be used with a laser cutter, and the reason for this varies between different materials. Some materials like plastics can emit toxic fumes when heated, some materials are highly reflective and can reflect the laser. If in doubt, a Ponoko engineer is here to help you.For example, some plastics such as PVC have no trouble being cut with a laser beam, but the resulting gasses formed from the intense heat can be highly toxic and thus dangerous for the environment. Other materials can release particulates and residue that can be harmful to optical components of a laser cutter (and thus reduce the amount of laser light hitting the workpiece). This is also dangerous for the laser cutter itself as reflective optical components that are covered with residue can become damaged through sudden thermal changes.Some materials can be highly reflective meaning that laser incident laser light bounces off the workpiece. This is particularly hazardous for a laser cutter as laser light can bounce back into the laser cutter itself and damage key components. CO2 lasers are susceptible to this damage whereas fiber lasers are more resilient.To ensure that customer parts are made to the highest quality, we have a specially curated range of laser-safe materials whose characteristics have been carefully documented. Additionally, we also pair materials to specific laser cutters to ensure consistent results between cuts. While we can cut custom materials for customers with specific requests, the part being cut must still be a laser-safe material. This is why we highly recommend the use of our stocked materials that have been thoroughly tested and proven.
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Is laser cutting suitable for mass production?

When it comes to mass production, laser cutting is rather unique in that it can be used for both prototyping individual parts and mid-scale production in quantities exceeding 10,000 units. Laser cutting’s ability to provide such capabilities stems from the speed at which lasers can cut, the lack of tooling or molds, and the low operating costs associated with laser cutters.Another major advantage of using laser cutters is that, unlike other manufacturing processes, a design file that has moved out of the prototyping phase requires no additional changes for mass production. This means that once a design has been locked in, it can be immediately produced in volume, and the flexibility of laser cutters allows for orders to be scaled with ease.Furthermore, laser cutting has the advantage that any design change needed can be submitted and implemented immediately. For comparison, any design changes to a plastic injected part typically requires thousands of dollars for a new mold, weeks to design the mold, and then an initial production run to test that the new part is correct.Our laser cutting service has been designed with speed and scalability in mind. Engineers looking to reduce the time of their development cycle can submit designs and have them manufactured the same day, and once a part is ready for mass production, we can take the same design file and immediately start work. Customers can choose the quantity they require and receive discounts of up to 93% (depending on the quantity), while also having the ability to contact our engineers should a design mistake be spotted - we’re standing by for you.Ponoko laser cutting also offers unique options that allow for parts to be market-ready including engraved designs, unique surface finishes, and bending that help to reduce the number of additional manufacturing steps needed.
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What are laser-cut living hinges and how can they be used to create 3D parts?

Living hinges are another popular method for creating 3D shapes using a 2D cutting process. Simply put, a living hinge is where the material has many thin lines cut from two parallel edges into the center of the material with a predefined space between each cut.The result of all of the cuts is that the length of the material across the living hinge is massively increased and thus exhibits great flexibility (and therefore can be folded). But while living hinges are aesthetically appealing and useful for creating a naturally flexible bend, it also reduces the strength of the part as less material is being used to hold it together. Living hinges are popular with cut metal, and cut wood.
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Does Ponoko deal with unusual and unique laser cutting projects?

Yes. If there is one thing that can be said about engineering projects, it's that there is always some unusual problem that needs to be solved whether it is the need for a non-standard material or the development of a unique fitting. To make matters worse, it can be challenging to find manufacturers willing to tackle these issues without facing serious compromises to the project. As a laser cutting business, we pride ourselves on tackling any project that comes our way. Whether our customers are startups, small businesses, or enterprise corporations, our team of experienced engineers and machine operators can provide professional consultation on design and manufacturing processes. With over 15 years of experience in the laser cutting industry, we have tackled numerous unique projects ranging from rapid testing kits for COVID to aerospace components experiencing extreme environments.
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Does Ponoko accept custom materials for laser cutting?

Yes, provided the material complies with our laser cutting requirements here. For example, the material thickness cannot exceed 12mm, must have a uniform core (i.e., must be a solid material with a consistent internal structure), and must be laser safe. Examples of materials that we cannot cut include PVC, rubber, glass, stone, and heat-resistant materials.Choosing materials for laser cutting is no small feat as not all materials are laser safe or cut well using lasers. To help simplify material selection, we have curated a list of over 200+ engineered materials that are guaranteed to meet the strict set of precision standards we offer. However, some projects may call for very specific materials whether it is because of their material properties, appearance, or availability.

Need something other than laser cutting? Check out our other services

Laser cutters are great for making 2D parts, but they aren’t always the best option for engineers. If you are looking for something different, check out our other manufacturing services, which include 3D printing for 3D prototypes, plastic injection molding for mass production of plastic parts, CNC milling for high-precision engineering applications, and our complete PCB fabrication and assembly.

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Custom parts delivered same day.
*Same day delivery (or money back) is available for orders using a limited selection of materials, placed by 11am PT Monday - Friday, for 1-100 parts to Bay Area USA locations. Same day shipping (or money back) available to USA & worldwide locations.