If you’re a product engineer or procurement specialist tasked with choosing a cutting method for sheet metal, wood, or plastics, you’ve probably wondered if laser cutting is the right fit. It’s one of the most versatile CNC processes out there—but how does it work? Which laser type should you pick? And when is it cheaper than alternatives like waterjet or plasma cutting? This guide answers all those questions with real-world examples, data, and actionable tips to help you make the best choice for your project.
What Is Laser Cutting? A Simple Breakdown
Laser cutting is a CNC (computer numerical control) process that uses a high-powered laser beam to cut, engrave, or drill materials. Unlike traditional cutting tools (which physically push through material), lasers work by focusing intense light energy onto a small spot—this melts, evaporates, or burns the material, creating clean, precise cuts.
Here’s a step-by-step look at how it works:
- Laser Generation: Inside a closed container, an electrical discharge stimulates a “laser material” (like carbon dioxide for CO₂ lasers) to create a high-density light beam.
- Beam Focusing: Optics (lenses or mirrors) narrow the laser beam to a tiny point (often just 0.1–0.3 mm wide) for maximum precision.
- Material Cutting: The CNC system controls the laser’s movement across the workpiece. As the beam hits the material, it vaporizes or melts the target area—leaving a smooth edge.
- Debris Removal: A small air jet blows away melted material (called “dross”) to keep the cut clean.
The result? Parts with minimal post-processing needs—no sanding or filing required for most applications.
3 Types of Laser Cutting Machines: Which One to Choose?
Not all laser cutters are the same. The three main types—CO₂ lasers, fiber optic lasers, and YAG lasers—each have unique strengths, weaknesses, and ideal uses. Below’s a detailed comparison to help you pick the right one.
Laser Type Comparison Table
| Laser Type | Key Advantages | Main Disadvantages | Best For Materials | Ideal Applications |
|---|---|---|---|---|
| CO₂ (Carbon Dioxide) | • High energy efficiency • High power output ratio • Low cost for non-metals | • Not suitable for thick sheet metal • Slower than fiber lasers for metals | Paper, wood, plastic, thin metals (up to 3mm steel) | Engraving signs, cutting plastic parts, drilling thin materials |
| Fiber Optic | • Ultra-fast cutting speed • High precision (tolerances: ±0.05mm) • High efficiency for metals | • Higher upfront cost than CO₂ lasers • Less effective for thick non-metals | Steel, stainless steel, aluminum, copper | Cutting sheet metal parts (automotive, aerospace), metal signage |
| YAG (Yttrium-Aluminum-Garnet) | • Great flexibility • Portable (smaller machines) • Works with both metals and non-metals | • Lower energy efficiency • Higher maintenance costs | Thin metals, plastics, ceramics | Prototyping small parts, on-site cutting jobs |
Real-World Example: A Sheet Metal Supplier’s Choice
A supplier making 1mm stainless steel brackets for automotive use initially used a CO₂ laser. While it worked, each bracket took 45 seconds to cut—too slow for their 10,000-unit order. They switched to a fiber optic laser, which cut the same bracket in just 12 seconds. The faster speed let them fulfill the order in 3 days (instead of 10) and reduced labor costs by 65%.
The lesson? For metal parts, fiber optic lasers are worth the higher upfront cost—especially for high-volume runs.
What Materials Can You Cut with Laser Cutting?
Laser cutting works with hundreds of materials, but it’s most effective for thin sheets (since thick materials take longer to cut and use more energy). Below’s a breakdown of common materials, their maximum cuttable thickness, and typical uses.
Common Laser-Cut Materials & Specs
| Material | Maximum Cut Thickness | Laser Type Best Suited For | Key Benefits | Example Uses |
|---|---|---|---|---|
| Aluminum | 15mm | Fiber optic, YAG | Lightweight, corrosion-resistant | Aerospace brackets, automotive parts |
| Steel (Mild) | 6mm | Fiber optic | Strong, low cost | Structural parts, tool bodies |
| Stainless Steel | 8mm | Fiber optic | Rust-resistant, durable | Kitchen appliances, medical tools |
| Copper & Brass | 5mm | Fiber optic (high power) | High conductivity | Electrical components, decorative parts |
| Wood (Plywood) | 25mm | CO₂ | Easy to engrave, low cost | Furniture parts, signage |
| Plastic (ABS, HDPE) | 10mm | CO₂ | Clean cuts, no melting residue | Toy parts, electronics casings |
Critical Note: Avoid These Materials
Some materials release toxic fumes when laser-cut—never use laser cutting for:
- PVC (releases chlorine gas)
- Polycarbonate (melts instead of vaporizing, leaving a sticky residue)
- Foam (can catch fire from the laser’s heat)
Laser Cutting vs. Other Cutting Methods: Pros & Cons
Laser cutting isn’t the only option—you’ll often compare it to plasma cutting (fast for thick metals) and waterjet cutting (high precision, no heat damage). Below’s how they stack up.
Cutting Method Comparison Table
| Feature | Laser Cutting | Plasma Cutting | Waterjet Cutting |
|---|---|---|---|
| Precision (Tolerance) | ±0.1–0.2mm (best for fiber optic) | ±0.5–1.0mm | ±0.05–0.1mm (most precise) |
| Material Flexibility | Works with metals, wood, plastics, etc. | Best for thick metals (10mm+) | Works with nearly all materials (even stone) |
| Heat-Affected Zone (HAZ) | Small (minimal warping) | Large (metal can warp) | None (cold cutting) |
| Cost (Per Hour) | $150–$300 (fiber optic: $250–$300) | $100–$200 | $300–$500 (most expensive) |
| Post-Processing Needs | Minimal (no sanding for most parts) | High (needs grinding to smooth edges) | Minimal (clean cuts) |
| Can It Engrave? | Yes (CO₂ and fiber optic) | No | No |
When to Choose Laser Cutting Over Alternatives
- You need both cutting and engraving (e.g., branded metal parts).
- Your material is thin (under 8mm for metals) and needs tight tolerances.
- You want to avoid warping (laser’s small HAZ is better than plasma).
For example, a jewelry maker uses CO₂ laser cutting to create 0.5mm stainless steel pendants with engraved designs. Waterjet cutting could make the pendants, but it can’t engrave—so the maker would need a second process, adding cost and time. Laser cutting does both in one step.
How Much Does Laser Cutting Cost?
Laser cutting costs depend on three factors: laser type, material, and part complexity. Below’s a breakdown of typical costs to help you budget.
Cost Breakdown by Laser Type
| Cost Factor | CO₂ Laser | Fiber Optic Laser | YAG Laser |
|---|---|---|---|
| Machine Cost (New) | $20,000–$80,000 | $50,000–$200,000 | $30,000–$100,000 |
| Operating Cost (Per Hour) | $50–$100 (energy + maintenance) | $80–$150 | $70–$120 |
| Cost Per Part (1mm Steel Bracket) | $0.75–$1.00 | $0.30–$0.50 | $0.50–$0.70 |
Pro Tip: Reduce Costs with Nesting Software
“Nesting” is a technique that arranges multiple parts on a single sheet of material to minimize waste. For example, a sheet of 1m x 1m steel can fit 20 small brackets instead of 15 if nested properly. Most laser cutting shops use nesting software—ask for this to cut material costs by 15–25%.
Yigu Technology’s Perspective on Laser Cutting
At Yigu Technology, we see laser cutting as a “one-stop” solution for thin-sheet projects—especially when precision and speed matter. For clients, we start by matching the laser type to their material: CO₂ for non-metals, fiber optic for metals. We also emphasize upfront design checks—simple tweaks (like reducing part complexity) can cut cutting time by 30%. For example, we helped a client rework a stainless steel part’s design to remove unnecessary holes, lowering their per-part cost from $1.20 to $0.85. Laser cutting works best when it’s planned—we help bridge the gap between design and production to maximize efficiency.
FAQ About Laser Cutting
1. Can laser cutting handle thick materials (over 15mm aluminum)?
It can, but it’s not cost-effective. Thick materials take longer to cut (increasing labor costs) and use more energy. For materials over 15mm, waterjet cutting is better—it’s faster and avoids heat damage.
2. Is laser cutting cheaper than CNC machining for small parts?
For thin, flat parts (like brackets or signs), yes. Laser cutting is faster (no tool setup needed) and has lower waste. For 3D parts or thick materials, CNC machining is better—laser cutting can’t handle deep, complex geometries.
3. Do laser-cut parts need post-processing?
Most don’t. Laser cutting leaves smooth edges, especially with fiber optic lasers (for metals) or CO₂ lasers (for plastics). The only exception is thick metals (over 6mm steel), which might need light grinding to remove small dross.
