Applies to: all AEON CO2 lasers with a rotary
This guide covers the basics of setting up a file for a full wrap design on a tumbler or similar cylindrical object. Use it any time your design wraps the entire circumference of the item.
What you need
- Rotary device: chuck style (recommended) or roller style
- Item to engrave
- Measuring device: calipers (recommended) or a soft tape measure
- LightBurn software
- A design to engrave
Before you start
This guide assumes your machine is already set up for rotary jobs. If you need help setting up a rotary, see our rotary guides. For help choosing settings, see Optimizing Tumbler Settings.
Video: AEON Laser USA brand ambassador Emily Caroline (That Mom with a Laser) has a video on engraving a full wrap design on a tapered tumbler.
What is a full wrap?
A full wrap is a design that completely encircles the outer surface of a cylindrical or curved object, such as a tumbler, bottle or mug. The design covers the whole circumference for a 360 degree effect. There are two types:
- Seamless wrap: the edges meet perfectly with no visible gap or overlap, so the pattern runs continuously around the object.
- Non-seamless wrap: the edges meet with a visible seam, gap or overlap that marks the start and end of the pattern.
The images below show the difference. In the seamless close-up, the edges align perfectly. In the non-seamless design, the edges do not touch, which leaves a visible break.
Which rotary is best for a full wrap?
Chuck rotaries are recommended. They hold the item securely, which gives consistent rotation and precise alignment. That matters most for seamless wraps, where the edges must line up exactly.
Roller rotaries can run a full wrap, but they are less suitable. The item can slip, especially if it is heavy or tapered, and that costs the precision a full wrap needs.
Take the measurements
Accurate measurements decide the size of the design and may also be needed for the rotary settings, especially with a chuck rotary. You need two:
- The diameter (or circumference) of the item
- The height of the engravable area
Record both carefully for the next step. Calipers are recommended, though a cloth ruler will also work.
Note: A tapered item has two different circumferences. Use the larger diameter or circumference. LightBurn has a built-in tool that adjusts a design for the taper. See LightBurn’s documentation on the Taper Warp tool.
Enter the measurements in LightBurn
The measured height becomes the total width of the file. That can seem backwards, but the height of the cup lies along the X axis of the machine while it engraves, and the file is rotated to match before you send it. For example, if the engravable area is 237.187 mm, rotate the file as for any rotary job and set its width to that value.
Enter the measured diameter (or circumference) in the rotary setup section of LightBurn, as shown below. This value sets how far the chuck rotary spins. Accuracy matters most for a seamless wrap, because the edges of the file must align exactly. A non-seamless design is more forgiving.
Caution: An inaccurate diameter makes the chuck rotary turn the item too little or too much. If the value is too low, the rotary turns the item too far, and the design overlaps or stretches. If the value is too high, the rotary turns the item too little, and the design has gaps or looks compressed.
When you enter the diameter, LightBurn calculates the circumference. Set the height of the file to match the circumference, because that is the total distance around the cup. For example, a cup with a diameter of 101.6 mm has a circumference of 319.186 mm. For a non-seamless design, you can make the height 1 to 2 mm shorter so nothing overlaps.
Once the file is edited and the rotary settings are updated, send the file to the machine and run it.
Set up the rotary and the item
- Focus: the whole length of the item must stay within the focal range of the laser. For a non-tapered cup, focus as usual. For a tapered cup, adjust the angle of the cup on the rotary so the surface stays within a usable focal range along its length.
- Squareness: make sure the cup is square to the gantry. If the rotary or the item is misaligned, the design engraves at an angle, which is a particular problem for seamless wraps.
- Clearance: check that the item has full clearance for the whole job, especially cups with handles or mounting tabs that could hit the laser head. To gain clearance, use a lens with a longer focal length or remove hardware from the laser head. A 2.5 inch lens is a common choice for a full wrap on a 40 oz tumbler.
- Seam placement: where you can, put the seam in a less noticeable place. On a cup with a handle, line the seam up with the handle to hide it and mask minor imperfections.
Summary
A full wrap depends on careful preparation: accurate measurements, the right values in LightBurn, and an item that is square, in focus and clear of obstructions. Get those right and you can engrave clean, fully wrapped designs on cylindrical items.
AEON Laser USA is not responsible for any damages or injuries that may result from following these suggestions. Use caution at all times.
Need a hand?
Email support@aeonlaser.us or call 321-260-2325. More ways to reach us are on the Support page.