Laser cutting uses a focused beam to cut intricate shapes and fine detail from paper, card and rigid materials. It produces results that are impossible with conventional die-cutting and handles both short runs and complex prototypes. We operate laser cutting in-house at our Marrickville production facility.
What is laser cutting
A laser cutter directs a high-energy beam along a path defined by vector artwork, typically from Adobe Illustrator. The beam melts, burns or vaporises the material along the cutting line, leaving a clean, precise edge.
Different laser intensities produce different effects. Full power cuts through the material. Reduced power scores or creases without cutting. Very low power etches the surface for a subtle engraved effect. These intensities are controlled by assigning different colours in the artwork file.
When to use laser cutting
Laser cutting is the right method when the design includes shapes, cutouts or patterns that are too intricate or too small for a conventional die-cut. Common applications include invitation cards with filigree patterns, packaging windows, pop-up elements, architectural model components, POS display structures and industrial prototypes.
There is no tooling cost. The laser follows the artwork file directly, so every job can be different without additional setup. This makes laser cutting ideal for prototyping, one-off pieces and short runs where die costs are not justifiable.
Materials
We laser cut paper, card, board, acrylic, perspex, wood, MDF, felt, fabric and some plastics. Material thickness and type determine the laser settings. We test unfamiliar materials before committing to a production run.
Some materials produce clean, sealed edges when laser cut. Others may show slight discolouration or charring at the cut line. We advise on material suitability at the quoting stage.
Design considerations
Artwork must be supplied as vector paths. The laser follows these paths exactly, so line placement determines the cut position. Avoid placing cuts too close to the edge of the sheet or too close to each other, as the material between cuts may become fragile.
Minimum line spacing is approximately 1mm to 2mm depending on material thickness. Very fine details are achievable but material integrity must be considered. We review all laser cutting artwork before production and flag potential structural issues.
How we produce laser cutting
The artwork is loaded into our laser cutting software. Material is positioned on the cutting bed. The laser follows the vector paths at the specified power settings. Finished pieces are removed, inspected and cleaned if needed.
Turnaround is fast. Simple jobs can be cut and shipped within 1 to 2 working days after artwork approval.
Need precision-cut shapes for an invitation, prototype or display project? Get in touch to discuss laser cutting.
Frequently Asked Questions
What materials can be laser cut?
Paper, card, board, acrylic, perspex, wood, MDF, felt, fabric and some plastics. We test unfamiliar materials before production.
Is there a minimum order quantity?
No. Laser cutting has no tooling, so single units and prototypes are commercially viable.
How fine can the detail be?
Very fine. The laser beam width is less than 0.5mm. Detail is limited more by material strength than by cutting precision.
Does laser cutting leave burn marks?
Some materials show slight discolouration at the cut edge. Paper and card typically cut cleanly. Wood and MDF may show a light char line. We advise on expected results for each material.
What is the difference between laser cutting and die-cutting?
Die-cutting uses a metal blade pressed into the material. It requires a custom die and suits long runs. Laser cutting follows a digital file with no tooling and handles finer detail, but runs slower on high volumes.