Acrylic production guide
CO2 laser settings for acrylic should be used as documented starting references rather than universal presets. This guide combines factory test data with the material, focus, airflow and machine factors that determine cut completion, edge quality and repeatability.
Acrylic is one of the materials that demonstrates the practical strengths of a CO₂ laser particularly well. Clear sheet can be cut cleanly, edges can emerge with a polished appearance, and intricate letters, display parts and layered signs can be produced without mechanical cutting pressure.
However, a sheet from another supplier may produce a cloudy edge, excessive melting at a corner or an incomplete cut when the same settings are used. This variation is normal: “acrylic” describes a family of sheet products, while a laser setting describes one tested combination of material, machine and process.
The objective is therefore not to find one universal number, but to establish a repeatable process: identify the sheet, select a defensible starting range, test one variable at a time, inspect the complete contour and save a preset for that specific stock.
CO2 laser settings for acrylic: the useful starting references
The AEON factory sheet supplied in July 2026 separates “best speed” from “maximum speed.” That distinction matters. Maximum speed describes the fastest recorded reference for separation. Best speed is the factory's quality-oriented label. Neither term is a promise, because the source file does not identify the exact acrylic grade, lens, focus position, machine model or edge-acceptance method.
The complete source set spans 25W to 200W and acrylic from 3mm to 40mm. The table below intentionally shows the 60W, 100W, 130W and 150W columns that align most closely with current U.S. AEON cutting configurations. It does not invent a 45W value for the MIRA 5S, and it does not extrapolate the data to the 260W Super NOVA option.
| Acrylic thickness | 60W | 100W | 130W | 150W |
|---|---|---|---|---|
| 3mm / 0.118 in. | 15 | 25 | 30 | 35 |
| 5mm / 0.197 in. | 7 | 10 | 12 | 15 |
| 8mm / 0.315 in. | 3 | 6 | 8 | 10 |
| 10mm / 0.394 in. | 2 | 4 | 5 | 7 |
| 15mm / 0.591 in. | 0.8 | 2 | 3 | 4 |
| 20mm / 0.787 in. | 0.3 | 0.7 | 1 | 1.5 |
For comparison, the factory “maximum speed” values were 20, 30, 35 and 40mm/s for 3mm acrylic at 60W, 100W, 130W and 150W. At 10mm, they were 4, 7, 8 and 11mm/s. The gap between “maximum” and “best” is useful: a cut that separates successfully is not automatically suitable for production.
Lower-power estimate
Factory speed × chosen power ÷ 95. Example: the 100W/3mm best-speed reference is 25mm/s at 95%. At 80%, the initial estimate is 25 × 80 ÷ 95 ≈ 21mm/s. Test above and below it; do not treat the calculation as a guaranteed conversion.
Why there is no responsible universal preset
Displayed percentage is not measured optical wattage. Two nominally 100W tubes may not deliver identical output after different operating histories. A clean 2-inch lens and a contaminated lens will not put the same energy into the sheet. Cast and extruded stock can share a thickness label but respond differently. Even the protective film can change residue and flame behavior.
The chart therefore answers one question: Where is a sensible place to begin testing? It does not answer the more valuable question: Which documented setting will produce a repeatable, profitable part under your production conditions?
Cast vs. extruded acrylic changes the result
Acrylic is polymethyl methacrylate, or PMMA. It is also sold under familiar trade names, but the brand name alone does not tell you whether the sheet is cast, extruded, impact modified, mirrored, laminated or formulated for a special application.
| Material | Typical laser behavior | Production question |
|---|---|---|
| Cast acrylic | Often develops a white or frosted engraving with strong contrast; thickness can vary more across the sheet. | Does the engraved appearance matter more than tight thickness consistency? |
| Extruded acrylic | Often cuts efficiently with a clear-looking edge; engraving may appear more transparent. | Is consistent sheet thickness and cutting throughput the priority? |
| Mirrored acrylic | Normally processed from the coated reverse side so the clear face remains protected. | What is the backing made from, and has the supplier confirmed laser compatibility? |
| Colored or specialty sheet | Pigments, fillers, laminates and impact modifiers can change absorption, odor, residue and edge color. | Do you have the technical and safety information for the exact product? |
CO₂ wavelength is well matched to clear acrylic, which is why a CO₂ laser can cut it while many visible-light diode systems struggle. If clear acrylic is central to the catalog, see our CO₂ laser vs. diode laser guide before comparing wattage claims.
Never laser-cut PVC or vinyl. Chlorine-containing fumes are hazardous and corrosive. Do not identify an unknown plastic by appearance or by a flame test in the laser. Obtain the supplier's safety and technical documentation first.
What creates a polished acrylic edge?
The glossy edge associated with laser-cut acrylic comes from controlled melting and resolidification along the cut wall. Too little energy can leave an incomplete or heavily striated cut. Too much heat can widen the kerf, round internal corners, deform small details and increase fire risk.
A good edge is a system result. Power and speed are only the most visible controls.
- Focus: the focal position changes where the beam waist sits through the sheet. Thick acrylic may benefit from a focus strategy different from thin engraved stock.
- Lens: a shorter focal length can support fine detail; a longer focal length can provide a deeper usable focus range for thicker material, with a different spot-size trade-off.
- Optics: residue on a lens or mirror wastes power and can create inconsistent results across the bed.
- Airflow: enough air movement is needed for flame control, but excessive top-side flow can chill the molten edge and reduce gloss in some setups.
- Extraction: fumes must leave the cut zone effectively. Poor exhaust can redeposit residue and obscure a process problem.
- Geometry: small holes, tight corners and nested details accumulate heat differently from a long straight cut.
- Sheet condition: stress, protective film, storage and actual thickness influence the result.
One pass or several?
A single pass can produce a cleaner wall because the edge experiences one continuous thermal event. Multiple passes may complete a cut beyond the practical one-pass range, but they add cycle time and can create visible steps or excess heat. The better production method is the fastest supervised process that repeatedly produces the accepted edge, rather than the method that produces the most impressive one-off thickness result.
Thick-acrylic capability claims require context. The current Super NOVA 16S page describes a 260W dual-core glass configuration as capable of cutting up to 2-inch acrylic. That is an official capability statement for a specific industrial configuration, not a settings promise for every acrylic grade, geometry or edge standard. A production buyer should still submit the real material and file for testing.
A material-test method you can repeat
Start with a small test that reflects the geometry you sell. A grid of straight rectangles is useful, but it can hide heat problems that appear in tiny holes, narrow bridges and closely spaced letters. Include at least one internal corner, one small circle, one narrow feature and a longer exterior contour.
- Identify the stock. Record supplier, product code, cast or extruded manufacture, color, finish, nominal thickness, actual measured thickness and protective film.
- Prepare the machine. Clean and inspect optics, verify focus, confirm airflow and extraction, and make sure the bed is free of combustible debris.
- Choose a conservative range. Use the nearest documented wattage and thickness only as a starting reference. Stay within the source's operating limits.
- Change one variable. Test speed across several steps while power, lens, focus and airflow remain fixed. Then adjust one other factor if necessary.
- Inspect more than separation. Record edge gloss, vertical striation, kerf, dimensional accuracy, small-detail distortion, residue, flame behavior and cleanup.
- Repeat the preferred result. A single good square is not a production preset. Run the setting again on a representative nested file and at more than one bed position.
- Save the complete recipe. Include date, machine, source, lens, focus method, material code, speed, power, passes, air and notes—not just two numbers.
LightBurn users can use the official Material Test workflow to organize speed and power combinations. Use it on the actual material after the machine has been prepared. A setting copied from another laser should remain a reference only; it does not replace testing on the actual machine and stock.
A setting record worth keeping
Supplier + acrylic code + type + color + measured thickness + machine + source + lens + focus + speed + power + passes + air + extraction condition + accepted edge standard + date.
Acrylic cutting troubleshooting
| Symptom | Check first | Do not assume |
|---|---|---|
| Incomplete cut | Actual thickness, focus, clean optics, alignment, source output, speed and bed support. | That increasing displayed power is automatically safe or efficient. |
| Cloudy or rough edge | Material type, speed/energy balance, focal position, lens, airflow and extraction. | That slower is always glossier; too much heat can make the result worse. |
| Melting at corners | Corner speed, power behavior, duplicate vectors and closely nested geometry. | That a straight-line test represents a detailed production file. |
| Flame or excessive smoke | Supervision, extraction, air assist, dirty bed, protective film and loose offcuts. | That flame is normal because the material is combustible. Stop and correct it. |
| Result changes across bed | Bed level, sheet flatness, optical condition, focus consistency and material thickness. | That a successful test in one corner proves full-bed repeatability. |
Which current AEON model fits an acrylic business?
Power affects cutting capacity, but working area often becomes the first practical limitation. A small shop can be highly productive on a compact machine when every product fits. A larger machine earns its floor space when nesting, sheet handling or long contours are already limiting output.
| Model | Glass source | Working area | Displayed price | Acrylic fit |
|---|---|---|---|---|
| MIRA 5S | 45W | 11¾ × 19¾ in. | $5,999 | Compact products, engraving and lighter cutting where footprint leads. |
| MIRA 7S | 60W | 19 11/16 × 27½ in. | $8,999 | Awards, signs and repeat batches needing more area and cutting capacity. |
| MIRA 9S | 100W | 23⅝ × 35½ in. | $11,999 | Growing production, larger signs and thicker-stock testing in a MIRA platform. |
| NOVA 14S | 130W | 35 7/16 × 55⅛ in. | $19,999 | Large-format signage and cutting-led daily production. |
| NOVA 16S | 150W | 39⅜ × 63 in. | $22,999 | Larger sheets, longer contours and high-throughput acrylic work. |
Prices above are live-site snapshots, not quotations. Promotions, availability, source options, freight, installation needs and taxes can change. Confirm the exact build on the product page and use the U.S. comparison page for current specifications.
The MIRA 5S should not be described as universally “too small”; it is simply the most compact model in the group. That can be exactly right for compact products and limited floor space. It becomes the wrong choice when normal parts or nesting layouts exceed its 11¾ × 19¾-inch work area.
MIRA 9S moves the current U.S. MIRA line to a 100W glass source, a 23⅝ × 35½-inch bed, built-in active cooling, autofocus, camera alignment and pass-through access. NOVA adds larger-format capacity. Super NOVA becomes relevant when acrylic cutting and fine, fast engraving both produce enough work to justify separate CO₂ sources in one platform. Read glass vs. RF CO₂ source before paying for a capability your order mix may not use.
Support and documentation affect settings repeatability
A material recipe is only valuable when the machine can repeat it. AEON Laser USA currently publishes a two-year machine warranty, lifetime U.S.-based support and live training. The warranty page says most repairs are resolved remotely by phone and email; it does not promise routine on-site checkups. Essential components are warehoused in the United States, with stated exceptions possible.
That model works best when the operator keeps good records. A support conversation that includes the material code, actual thickness, lens, focus method, settings, photos and the position on the bed is far more useful than “acrylic stopped cutting.” Review the current U.S. warranty terms before purchase.
Calculate the acrylic job, not only the cut
A faster cut does not automatically mean a more profitable product. A larger bed can improve nesting. A cleaner edge can remove flame-polishing labor. A camera can shorten positioned work. A more expensive sheet may reduce rejects. These effects belong in the same calculation.
Contribution per machine hour = (sales revenue − material − direct labor − variable costs) ÷ complete machine time
Use complete machine time: loading, camera alignment, cutting, unloading and any unavoidable cleanup. Then record yield per sheet and rejected pieces. A 100W machine may cut a contour faster than a 60W machine, but it creates value only if that time releases a real bottleneck. The more useful commercial measure is cost per sellable part.
- Use the supplier's normal sheet size in the nesting test.
- Include edge cleanup and masking removal in labor.
- Allow for rejected parts and material variation.
- Measure full batch time, not one short contour.
- Price finishing that the laser eliminates.
- Keep fire supervision in the workflow plan.
Three acrylic workshop demonstrations for additional context
Creator videos can show workflow and surface quality that a specification table cannot. They are not controlled guarantees. Verify the machine, source, material and disclosures, then repeat the test on your own stock.
Frequently asked questions
Can a CO₂ laser cut clear acrylic?
Yes. Clear acrylic absorbs CO₂ laser wavelength well. Thickness, speed and edge quality still depend on the source, actual output, material grade, lens, focus, optics, airflow and extraction.
What are good CO2 laser settings for acrylic?
Good settings are the fastest repeatable combination that fully separates your exact sheet while meeting the required edge and dimensional standard. Use documented factory data as a starting range, stay within the source's limits, then create and repeat a material test.
What speed should I use for 3mm acrylic?
In the July 2026 factory best-speed data at 95% power, 3mm references were 15mm/s at 60W, 25mm/s at 100W, 30mm/s at 130W and 35mm/s at 150W. These are starting references, not presets. The acrylic grade, lens, focus, actual output, airflow and accepted edge can change the final number.
What speed should I use for 10mm acrylic?
The same best-speed dataset lists 2mm/s at 60W, 4mm/s at 100W, 5mm/s at 130W and 7mm/s at 150W, all at the recorded 95% test condition. Thick acrylic increases the importance of focus, lens choice, optical condition, heat control and fire supervision.
Is cast or extruded acrylic better?
Neither is universally better. Cast is often favored when a frosted engraved appearance matters. Extruded stock may offer tighter thickness consistency and a clear-looking cut edge. Test the exact grade used in the product.
Why are acrylic edges cloudy?
Common causes include an unsuitable speed/energy balance, incorrect focus, a lens that does not suit the thickness, dirty optics, poorly tuned airflow, weak extraction, material variation or repeated passes. Change one variable at a time.
Can I leave protective film on acrylic?
Sometimes, if the film is confirmed laser compatible and the result is tested. Paper masking can reduce surface residue on some jobs. Unknown plastic film may melt, flame or produce unsuitable fumes. Ask the sheet supplier and never assume.
Which AEON is best for acrylic?
MIRA 5S and 7S fit compact products and smaller shops; MIRA 9S adds a 100W glass source and larger working area; NOVA fits larger-format cutting; Super NOVA is for production that genuinely benefits from both cutting-led glass and engraving-led RF capability. Select the model by working backward from part size, thickness, weekly volume and required edge quality.
Build a documented setting, not a copied preset
A settings chart can save time. It cannot know what is in your sheet, how clean the optics are, where the focus sits or what edge your customer will accept.
Start with documented data. Respect the operating limits of the exact source. Test the real material, inspect the full part and repeat the preferred result. Then save enough information that someone else in the shop can reproduce it six months later.
That is how CO2 laser settings for acrylic become a controlled and transferable production process.
Editorial note: This article was prepared with AI-assisted research and drafting, then reviewed and edited for AEON Laser USA. The publisher remains responsible for the final content. Factory acrylic data is reproduced from a July 2026 reference sheet whose exact acrylic grade, machine, lens, focus and acceptance method were not documented. Prices and specifications were checked on AEON Laser USA on August 20, 2026 and can change. Always verify the current product page, machine manual, source limits, material safety information and written quotation.
