Optimizing Score Line Settings

Applies to: all AEON CO2 lasers

This guide covers the factors that decide score line quality on a CO2 laser: power, speed and the properties of the material. By the end you will know how to balance them to avoid excess burning, reach the depth you want and keep your workflow efficient.

When to use this guide

Use it for any project that needs controlled, shallow marks that do not cut through the material, such as fold lines in packaging, guidelines for assembly or decorative accents. Come back to it if your scoring is inconsistent, chars too much, or leaves lines too weak to do their job.

What are score lines?

A score line is a shallow mark that does not fully penetrate the material, unlike a vector cut. Scoring gives precise marks for fold lines, guides and decoration. With the wrong settings the lines come out too deep, too light or with heavy burn marks, which affects both looks and function.

The balance of speed and power controls depth and limits damage to the material. High power at slow speed gives bold, well defined lines but can char. Too much speed at low power gives faint or incomplete marks, or a wobble in the line.

For more on how materials and settings interact, see Understanding Materials and Settings for a CO2 Laser.

Key factors

• Starting settings: a speed of 30 mm/s to 100 mm/s is generally a good starting point for scoring. Power depends on the material, the tube wattage and the result you want. Begin with mid-range speed and power, then fine-tune.
• Tube wattage: scoring settings depend heavily on the wattage of the laser tube. A 100 W tube cuts through 1/8” acrylic much faster than a 60 W tube, so adjust speed and power to match.
• Power and speed balance: power and speed together decide the depth and visibility of the line. Higher power at moderate speed gives a well defined mark, but a lower speed risks burning through and leaving a cut instead. Testing on scrap is the best way to find the right combination.
• Pitting: pits can form at the start and end of a line, where the laser first pulses. To compensate, set the Min power in LightBurn lower. A difference of 5–10% generally fixes it.
• Material: materials react differently to scoring. Wood tends to darken at higher power, and acrylic may melt too much at the same settings. Paper and thin materials do better with lower power and higher speed, which prevents warping and burning.
• Multiple light passes: for some jobs, several light passes give a better score than one deep pass. This helps with sensitive materials that build up heat.
• Air assist and focus: air assist directs air over the scoring area, which helps prevent burn marks and residue. Moving the focus slightly above or below the surface also changes the look of the score, softening or sharpening the line.

Test for the best settings

A controlled test is the way to find the best score settings for a material.

1. Take a sample piece of the material and design a simple test pattern, such as a series of straight lines at different speed and power settings.
2. Start in the middle of the recommended speed and power ranges.
3. Change one setting at a time and keep the others constant. If the score is too deep, raise the speed slightly or lower the power. If the score is too faint, lower the speed or raise the power.
4. Record each setting and its result so you can compare them.

Problems and fixes

The logic behind the adjustments

Every material has an optimal energy threshold. Too much power or too little speed overburns it. Too little power or too much speed leaves an ineffective score. The goal is a combination where the laser deposits enough energy for a clean, visible line without extra depth or damage.

Adjust methodically and study the results, and you can match the settings to the project and keep every score line consistent. Test again whenever you change materials or production conditions.

AEON Laser USA is not responsible for any damages or injuries that may result from following these suggestions. Use caution at all times.