Processing Plastics with CO2 Lasers

Synrad Applications Lab

( Version 1.03 )

Types of Laser Interactions with Plastics

There are 3 main types of material interactions when hit by the CO2 laser beam: Vaporization
The material vaporizes into gas residue which is blown out when cut. This is the cleanest cutting / marking process.

Melt Sharing
The material melts into molten droplets which are blown out when cut. There is typically some melt-back

Chemical Degradation
The plastic material chemically degrades typically releasing carbon smoke. The material chars and has soot residue
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Types of Plastic
There are two main types of commonly used plastics. It is important to distinguish between these two types as they have very different cutting and marking characteristics:

&
THERMOSETS
2012 Synrad Inc.

THERMOPLASTICS
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Types of Plastics - Thermosets

Thermosets
These plastics polymer chains have more connections and break down easily when heated. Thus, these plastics can not be successfully melted without damaging the molecular structure and the material changing color. Laser processing is primarily accomplished by chemical degradation. Consequently, there is discoloration and charring. These plastics typically cut and weld very poorly because of this but generally provide high contrast marks with some slight residue on the surface.

2012 Synrad Inc.

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Types of Plastics - Thermoplastics

Thermoplastics
These plastics polymer chains are simpler and have less bonding connections. Thus, the plastics can be melted easily without the polymer chains breaking down. Laser cutting is primarily accomplished by melt shearing. Marking is accomplished by melting the surface of the plastic to provide a slightly engraved mark. Since there is usually no material color change, the laser cuts are much better quality but conversely the laser marks have much lower visibility.

2012 Synrad Inc.

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Types of Plastics - Examples

Common plastics of each type include:

Thermosets:
Rubber based products Polyimide Epoxy Resins FR2/FR4

Thermoplastics:
Polypropylene Polyethylene Polystyrene Nylon ABS* Polycarbonate* PVC*

* Exhibits atypical behavior for a thermoplastic

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Types of Plastic - Exceptions

The following thermoplastics experience chemical degradation as well: ABS
Moderate Discoloration when cut; No color changes when marked.

Polycarbonate
Brown/Yellow charring.

PVC
Brown/Yellow charring.

Plastics which are glass filled

Glass-filled plastics typically will have black/brown color changes while the same unfilled plastic will not. A good example of this is Nylon.
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Summary Table of Plastic Types

Name ABS PMMA Plexiglas Also Known As Type Thermoplastic

(page 1)
Barcode Mark Successful No Sometimes: Depends on background color Sometimes: Depends on background color No

General Cut Quality Poor-Fair: Slight discoloration of cut edge Excellent: Clean vaporization with fire polished edge Poor: Some Charring

General Mark Quality Poor-Fair: Slightly engraved marks Good: Frosted white mark Good: Low power: White marks; High power: Charred engraved marks Fair-Good: Clean engraved marks Good: Dark marks on uncoated surface; Light marks on solder masks Fair-Good: Engraved marks with some meltback Good: Dark marks Good: Low Power: White/Transparent Mark. High Power: Brown/Yellow marks Fair-Good: Engraved marks with some meltback

Safety

Acrylic (Cast)

Thermoplastic

Bakelite Fluoropolymers FR4/FR2 PTFE, Teflon, EFTE PCB

Thermoset

Thermoplastic

Good: Some melt Poor: Brown Charring; sometimes degating is successful Good: Moderate melt Fair-good: Some discoloration of cut edge;

Thermoset

Yes

Nylon Nylon (Glass Filled) Lexan, Calibre, Makrolon, Panlite, Makrolife Mylar, PET, PETE, PETG

Thermoplastic

No

Yes Thick smoke when cut

Polycarbonate

Thermoplastic

Poor: Brown Charring;

Yes

Polyester

Thermoplastic

Good: Some melt; PETG needs high assist gas pressure ~60psi

Sometimes: Depends on background color

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Summary Table of Plastic Types

Name Polyethylene Polyimide Polyoxymethylene Polypropylene Also Known As HPDE, MDPE, LDPE, UHMW Kapton POM, Delrin, Polyacetal Type Thermoplastic Thermoset Thermoplastic

(page 2)
Barcode Mark Successful No Yes No Sometimes: (2D codes) Formaldehyde gas

General Cut Quality Fair-good: Moderate to large melt Poor: Brown/Black Charring Good: Some melt Good: Some melt; Sometimes slight discoloration Fair-good: Moderate melt & residue Fair-good: Moderate melt & residue Fair-good: Moderate melt & residue Poor: Brown/yellow charring; VERY HAZARDOUS outgassing Good: Vaporizes with some residue

General Mark Quality Fair-good: Engraved marks with melt-back Fair-good: Dark marks with some soot residue Fair-good: Clean engraved marks Fair-good: Deep engraved marks & slight melt-back Fair-good: Engraved marks with some melt-back Fair-good: Engraved marks with melt-back; Wet residue Poor-Fair: Slightly engraved marks Good: Brown/Yellow marks; Some residue Good: Deep engraved marks with some residue

Safety

Thermoplastic

Polystyrene

Thermoplastic

No

Polysulfone

Thermoplastic

No

Polyurethane

No

HCN GAS

PVC

Vinyl

Thermoplastic

Yes

HCL GAS: DO NOT CUT! Dense sooty smoke.

Rubber

Thermoset

Sometimes: (2D codes)

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ABS
Name ABS Also Known As Type Thermoplastic General Cut Quality Poor-Fair: Slight discoloration of cut edge General Mark Quality Poor-Fair: Slightly engraved marks Barcode Mark Successful No Safety -

Cutting Example

Marking Example

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Acrylic
Name Acrylic (Cast) Also Known As PMMA Plexiglas Type Thermoplastic General Cut Quality Excellent: Clean vaporization with fire polished edge General Mark Quality Good: Frosted white mark Barcode Mark Successful Sometimes: Depends on background color Safety -

Cutting Example

Marking Example

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Bakelite
Name Bakelite Also Known As Type Thermoset General Cut Quality Poor: Some Charring General Mark Quality Good: Low power: White marks; High power: Charred engraved marks Barcode Mark Successful Sometimes: Depends on background color Safety -

Marking Example

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Fluoropolymers
Name Fluoropolymers Also Known As PTFE, Teflon, EFTE Type Thermoplastic General Cut Quality Good: Some melt General Mark Quality Fair-Good: Clean engraved marks Barcode Mark Successful No Safety -

Cutting Example
(teflon)

Marking Example
(teflon)

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FR4/FR2
Name FR4/FR2 Also Known As PCB Type Thermoset General Cut Quality Poor: Brown Charring; sometimes degating is successful General Mark Quality Good: Dark marks on uncoated surface; Light marks on solder masks Barcode Mark Successful Yes Safety -

Degate Example

Marking Example

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Nylon
Name Nylon Also Known As Type Thermoplastic General Cut Quality Good: Moderate melt General Mark Quality Fair-Good: Engraved marks with some melt-back Barcode Mark Successful No Safety -

Cutting Example
(left: fabric, right: mesh)

Marking Example

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Nylon (Glass-Filled)
Name Nylon (Glass Filled) Also Known As Type General Cut Quality Fair-good: Some discoloration of cut edge; General Mark Quality Good: Dark marks Barcode Mark Successful Yes Safety -

Cutting Example

Marking Example

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Polycarbonate
Name Polyester Also Known As Mylar, PET, PETE, PETG Type Thermoplastic General Cut Quality Good: Some melt; PETG needs high assist gas pressure ~60psi General Mark Quality Fair-Good: Engraved marks with some melt-back Barcode Mark Successful Sometimes: Depends on background color Safety -

Cutting

High Power Marking

Low Power Marking

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Polyester
Name Polyethylene Also Known As HPDE, MDPE, LDPE, UHMW Type Thermoplastic General Cut Quality Fair-good: Moderate to large melt General Mark Quality Fair-good: Engraved marks with melt-back Barcode Mark Successful No Safety -

Fabric Cutting Example

Film Cutting Example

Film Cutting Example

Marking Examples

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Polyethylene
Name Polyethylene Also Known As HPDE, MDPE, LDPE, UHMW Type Thermoplastic General Cut Quality Fair-good: Moderate to large melt General Mark Quality Fair-good: Engraved marks with melt-back Barcode Mark Successful No Safety -

Cutting Example

Marking Example

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Polyimide
Name Polyimide Also Known As Kapton Type Thermoset General Cut Quality Poor: Brown/Black Charring General Mark Quality Fair-good: Dark marks with some soot residue Barcode Mark Successful Yes Safety -

Cutting Example

Marking Examples

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Polyoxymethylene
Name Polyoxymethylene Also Known As POM, Delrin, Polyacetal Type Thermoplastic General Cut Quality Good: Some melt General Mark Quality Fair-good: Clean engraved marks Barcode Mark Successful No Safety Formaldehyde gas

Cutting Example

Marking Example

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Polypropylene
Name Polypropylene Also Known As Type Thermoplastic General Cut Quality Good: Some melt; Sometimes slight discoloration General Mark Quality Fair-good: Deep engraved marks & slight melt-back Barcode Mark Successful Sometimes: (2D codes) Safety -

Cutting Example

Marking Example

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Polystyrene
Name Polystyrene Also Known As Type Thermoplastic General Cut Quality Fair-good: Moderate melt & residue General Mark Quality Fair-good: Engraved marks with some melt-back Barcode Mark Successful No Safety -

Cutting Example

Marking Example

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Polyurethane
Name Polyurethane Also Known As Type General Cut Quality Fair-good: Moderate melt & residue General Mark Quality Poor-Fair: Slightly engraved marks Barcode Mark Successful No Safety HCN GAS

Film Drilling Example

Foam Cutting Example

Marking Example

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PVC
Name Also Known As Type General Cut Quality Poor: Brown/yellow charring; VERY HAZARDOUS out-gassing General Mark Quality Good: Brown/Yellow marks; Some residue Barcode Mark Successful Safety HCL GAS: DO NOT CUT! PVC Vinyl Thermoplastic Yes

Marking Example

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Rubber
Name Rubber Also Known As Type Thermoset General Cut Quality Good: Vaporizes with some residue General Mark Quality Good: Deep engraved marks with some residue Barcode Mark Successful Sometimes: (2D codes) Safety Dense sooty smoke.

Cutting Example

Marking Example

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Thank you!

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