Laser Cutter Tutorial¶

Objective¶

Laser Cutters are planar gantry machines that use a high power laser to burn through material. Most modern machines are CNC and use software to translate a 2D design into instructions to automatically move a head along an XY gantry.

In this tutorial, we will:

• Learn the process to set up and clean up the Omtech 100 Watt laser cutter in the Outback.
• Create a nametag you can wear around town.
• Do all of the above without burning down the building or suffocating on toxic fumes .

Procedure¶

Install Lightburn¶

Lightburn is a design and control software used to operate laser cutters. It allows users to import vector and image files, adjust settings like power and speed, and organize cut and engrave layers. Lightburn is widely used in engineering and fabrication labs due to its precision, compatibility with many machines, and intuitive interface for both beginners and advanced users.

1. To get started with laser cutting, you'll need to install Lightburn, the software we’ll use to prepare and send your design files to the laser cutter.

2. Once installed, you can begin a free trial of Lightburn.

Design Your Name Tag¶

Design your name tag in Onshape.

We recommend starting from this example project. You can copy it and make modifications—change the shape, add your name, or include a small graphic.

Transfer Design¶

1. Export your DXF file from Onshape

   • Select the face of your name tag
   • Right-click and choose Export as DXF/DWG...

   Not letting you export?

   Ensure you have a face selected while exporting.

2. Import DXF into Lightburn

   Note

   If your design appears very small, your units are likely set to millimeters. Multiply the width/height by 25.4 to scale to inches.

Configuring Lightburn¶

1. Separate Inner and Outer Cuts with Colors

   Each color in Lightburn represents a separate layer with its own speed, power, and mode (cut, engrave, etc.). By default, Lightburn will assign all lines as the same color, so be sure to change it before proceeding.

   • Use one color for internal features (like holes or text).
   • Use a different color for the outer shape.

   If the inner layer is not at the top of the layer stack, drag it to the top to ensure it is cut first.

   Why cut inner features first?

   If the outer cut is done first, the material may shift or fall, ruining the accuracy of your internal cuts or engravings.

2. Assign Speed, Power, and Mode for Each Layer

   Once your layers are color-coded:

   • Select each layer from the Cuts/Layers window.
   • Set the speed (how fast the laser moves) and power (how intense the laser is).

   Example settings for 1/4" Baltic Birch:

   • 0.2 in/s
   • 40% power

   Note

   The correct settings depend on your material. Refer to the speed and power table for tested values.

Machine Setup¶

• Find the material you want. For this particular project, we will use 1/4" thick Baltic Birch. This high-quality wood has few voids and knots, and the consistent density helps when applying a constant power to cut through the material.

• Power on the machine. Make sure the laser cutter is powered on. The front panel allows you to move the head around as well as run files from a USB drive, but we won't use any features for this tutorial.

• Set table height. The laser is focused to a specific point below the head. We use a 3d printed stick to align the top of middle ridge of the laser head with the top of the material, as shown. If the target is too close or too far away, the laser power is focused on a larger area and is usually unable to cut cleanly, if at all, through the material.
  
  The height is adjusted manually with the knob on the front right of the bed.

Connect to Machine¶

1. Connect USB cable Plug the USB cable from the laser cutter into your computer. If your laptop lacks a standard USB port, adapters are available.

2. Frame your design on the material

   Framing options

   • The default frame tool (left icon) draws a simple rectangular outline around your entire job.
   • The contour frame tool (right icon) follows the actual shape of your design, offering a more precise preview—especially useful for irregular or curved cuts.
     
     

   Warning

   The small red laser dot is a nominal marker and does NOT correspond precisely with the actual invisible IR laser. The real laser is perfectly aligned with the lens on the gantry, and may be slightly forward or behind the red dot.

3. Adjust placement as needed If your design is not aligned correctly on the material:

   • Move the material on the bed, or
   • Reposition the design within Lightburn

   Then re-run the frame process until everything lines up as expected.

Start Cut¶

Once you have followed all of the instructions, you are ready to go! Press "Start", sit back, and relax while the laser cutter does all the hard work!

Cleanup¶

After your cut is complete, it's important to leave the laser cutter and workspace clean and ready for the next user. Proper cleanup not only extends the life of the equipment, but also ensures safety and smooth operation for everyone.

1. Remove your finished material
   • Carefully take your workpiece off the bed.
   • Be sure to collect any small pieces that may have fallen through or been left behind.
2. Clear leftover scraps and debris
   • Remove any small bits of wood, charred pieces, or dust.
   • Pay special attention to the honeycomb bed — debris stuck here can interfere with future cuts or become a fire hazard.
3. Return tools and accessories
   • Put the focusing tool, USB cables, and any other borrowed tools back in their designated spots.
   • If you used tape or magnets to hold down material, return them to the Annex area.

Takeaway¶

Congratulations! You are now ready to make anything you want on the laser cutter.

Always check the allowable materials if you are unsure, as some plastics do not cut well or off-gas toxic fumes, such as PVC or polycarbonate

Further Reading¶

• todo Design references/tutorial
• Laser cutter reference page
• Permitted laser cutter materials