Best Acrylic for Laser Cutting: Colours, Thickness and Tips
Cast acrylic is the best acrylic for laser cutting. It cuts with a clean, flame-polished, glossy edge and engraves to a frosted white that contrasts well. Extruded acrylic cuts fine but engraves clear rather than white and can be more prone to melting. For lettering, shapes and signage, choose cast acrylic every time.
Acrylic is the most popular material on a laser cutter, but not all acrylic behaves the same. The cast-versus-extruded choice makes the biggest difference to your results. Here is what to buy and how to get clean cuts.
Cast vs extruded acrylic for laser cutting
This is the single most important choice. Cast acrylic is made in moulds and has a slightly less uniform thickness, but it laser-cuts and engraves beautifully. Extruded acrylic is made in a continuous process with very even thickness, which is handy for machining, but it does not engrave white and can gum or melt more on the laser.
| Cast acrylic | Extruded acrylic | |
|---|---|---|
| Cut edge | Clean, glossy, flame-polished | Clean but can melt more easily |
| Engraving | Frosted white, high contrast | Clear, low contrast |
| Colour range | Wide, including effects | Narrower |
| Best for lasering | Yes | Workable, not ideal |
What thickness of acrylic should you laser cut?
Match thickness to the job and your machine’s power. Thin sheet cuts fast and suits detailed work; thicker sheet needs more power and slower speeds.
| Thickness | Best for |
|---|---|
| 2mm | Detailed lettering, jewellery, small parts, keyrings |
| 3mm | Signage, shapes, most general laser work |
| 5mm | Freestanding letters, sturdier parts, edge-lit pieces |
| 6–10mm | Chunky letters and signs; needs a more powerful laser |
Which colours laser cut best?
All cast coloured acrylics cut well, and because the colour runs through the sheet, cut edges and engraving stay on-colour. Fluorescent and edge-glow colours give a bright cut edge that suits edge-lit signage. On solid colours, engraving shows as a frosted mark, which reads clearly on black, dark blue and other deep shades. Mirror acrylic cuts cleanly too, though engraving removes the mirror layer to leave a frosted mark.
Laser cutting tips for clean results
A few habits make the difference between a rough cut and a polished one:
- Keep the protective film on the back to guard the finish, and consider removing the top film if you want the cleanest edge.
- Use air assist to reduce flaming and keep the edge clear.
- Cut slower at higher power for a polished edge, rather than fast passes that leave ridges.
- Do a test cut on an offcut to dial in speed and power for your machine and thickness.
- Never laser PVC or polycarbonate. PVC releases chlorine gas that damages you and the machine, and polycarbonate cuts poorly and yellows. Stick to acrylic.
Frequently asked questions
Is cast or extruded acrylic better for laser cutting?
Cast. It cuts with a glossy, flame-polished edge and engraves to a frosted white with good contrast. Extruded works but engraves clear and can melt more, so cast is the better buy for laser work.
Can you laser cut coloured and mirror acrylic?
Yes. Cast coloured and mirror acrylics laser-cut cleanly. Because the colour runs through the sheet, cut edges stay on-colour, and engraving leaves a frosted mark.
What acrylic thickness is easiest to laser cut?
2mm and 3mm are the easiest and most popular, cutting quickly with detail. Thicker sheet from 5mm up needs more laser power and slower speeds.
Why should you never laser cut PVC?
PVC releases corrosive chlorine gas when lasered, which harms your health and corrodes the machine. Always confirm your sheet is acrylic, not PVC, before cutting.
Does laser-cut acrylic need polishing?
Usually not. Cast acrylic comes off the laser with a glossy, flame-polished edge, which is one of the main reasons it is so popular for signage and display work.
Order cast acrylic for laser cutting
We supply cast acrylic in a wide colour range, cut to size and ready for the laser, delivered across the UK. Browse the coloured acrylic range or read our guide on cast vs extruded acrylic for more detail.