CO2 and Diode Laser Material Settings Reference: Speed, Power, and Passes for 50+ Materials

How to Use This Reference

This guide provides starting-point settings for laser cutting and engraving common materials on CO2 (40W-80W) and diode (5W-20W) lasers. All values are starting points — your actual optimal settings will vary based on your specific machine's calibration, lens condition, air assist strength, and material batch. Always test on scrap before committing to a final piece. Values are organized by material type with notes on safety considerations and post-processing.

Understanding the Settings

• Speed (mm/s): How fast the laser head moves. Higher speed = less energy delivered = shallower cut or lighter engrave.
• Power (%): Percentage of maximum laser power. Higher power = deeper cut/darker engrave. Never exceed 100% on your power supply for extended periods.
• Passes: Number of times the laser traces the same path. Multiple passes cut thicker material but can increase charring.
• Air Assist: Compressed air flowing at the cut point. Essential for most materials to reduce charring and improve cut quality.
• Focus: The distance from lens to material surface. For cutting thick material, some operators defocus slightly (+1-3mm) for a wider kerf and cleaner edge.

Wood and Wood Products (CO2 Laser, 50-60W)

MaterialThicknessSpeedPowerPassesNotes Balsa1/16" (1.5mm)40025%1Very light; may need hold-down Balsa1/8" (3mm)30035%1Cuts cleanly at these settings Birch plywood1/8" (3mm)2065%1Good air assist essential; some char on edges Birch plywood1/4" (6mm)875%1May need 2 passes for clean cut Baltic birch1/8" (3mm)2560%1Better glue quality than standard plywood MDF1/8" (3mm)1570%1Very dirty cut; heavy smoke; excellent air assist mandatory MDF1/4" (6mm)680%1-2Dark edges; consider painting edges after cut Hardboard/Masonite1/8" (3mm)1275%1Similar to MDF; very dense Hardwood (oak, maple)1/8" (3mm)1870%1Beautiful edges; minimal char Hardwood (oak, maple)1/4" (6mm)780%1Clean cut; slight amber color on edges Hardwood (walnut, cherry)1/8" (3mm)2065%1Excellent results; dark wood shows less char Cork sheet1/8" (3mm)3045%1Cuts very easily; light engraving possible Wood veneer1/42" (0.6mm)10030%1Very fast; minimal power; watch for fires with thin material

Acrylic and Plastics (CO2 Laser, 50-60W)

MaterialThicknessSpeedPowerPassesNotes Cast acrylic (clear)1/8" (3mm)1565%1Flame-polished edges; beautiful results Cast acrylic (clear)1/4" (6mm)675%1Clean edge; slight taper Cast acrylic (clear)1/2" (12mm)285%1Slower for clean through-cut Cast acrylic (colors)1/8" (3mm)1860%1Colors cut easier than clear; less flare-up Extruded acrylic1/8" (3mm)2055%1Cuts easier than cast; edges less polished Mirrored acrylic1/8" (3mm)1565%1Cut with mirror side DOWN Two-tone acrylic (Rowmark)1/16" (1.5mm)8035%1Engrave top layer to expose contrast color Polycarbonate/Lexan1/16" (1.5mm)1080%1Discolors heavily; poor edge quality; CO2 not ideal PETG1/16" (1.5mm)1270%1Melts easily; may need multiple passes at lower power Delrin/Acetal1/8" (3mm)1065%1Excellent cut quality; low friction material ABS1/8" (3mm)1260%1Produces foul-smelling smoke; ventilate extremely well

Engraving Settings (CO2 Laser, 50-60W)

MaterialSpeedPowerResult Wood (light)400-60025-35%Light brown mark, good contrast Wood (dark)300-40035-50%Deep black engraving Acrylic (clear)500-80015-25%Frosted white appearance Acrylic (black)400-60020-30%White/gray mark on black background Glass (flat)300-50045-65%Frosted white surface mark; apply wet paper towel first Slate200-40040-60%White/chalky mark on dark stone Granite/marble150-30050-70%Light mark; color depends on stone Anodized aluminum500-80030-45%Removes anodizing; bright aluminum against color Powder-coated metal300-50045-65%Removes coating; exposed metal underneath Leather (vegetable tan)400-60025-35%Dark brown/black mark Leather (chrome tan)500-70020-30%Less contrast than veg-tan Fabric (cotton/linen)600-100015-25%Brown mark; can cut at higher power Denim500-70020-30%White/bleached mark Rubber (stamp material)150-30035-50%Deep clean engraving; excellent detail

Metal Marking with CO2 Lasers

CO2 lasers cannot directly cut or engrave bare metal — the wavelength (10.6μm) reflects off metal surfaces. However, you can mark metal using sprays:

CerMark / Thermark Metal Marking

MetalSpeedPowerNotes Stainless steel300-50085-100%Best results; permanent black mark Aluminum (bare)200-40090-100%Works; mark is less durable than on steel Brass250-40090-100%Good contrast; permanent mark Chrome/plated300-50085-100%Excellent results on chrome Titanium250-40090-100%Creates colored oxidation marks at different powers

Process: Spray thin, even coat of CerMark. Let dry 5 minutes. Laser at high power. Rinse under water — unlased CerMark washes away, lased areas bond permanently to the metal.

Fiber Laser Settings (for comparison — different machine type)

MaterialSpeedPowerFrequency Stainless steel (deep engrave)100-20080-100%20-50 kHz Aluminum (annealing mark)200-40060-80%100-200 kHz Aluminum (deep engrave)100-20090-100%50-100 kHz Brass150-30080-100%20-50 kHz Plastic (marking)500-100030-50%20-50 kHz

Materials You Should NEVER Laser

MaterialWhy It's Dangerous PVC / VinylReleases hydrogen chloride and chlorine gas — corrodes machine, toxic to breathe, illegal in many areas ABSReleases cyanide compounds when cut; extremely toxic smoke PolycarbonateReleases bisphenol-A fumes; poor cut quality; yellows heavily Fiberglass / carbon fiberReleases glass fibers and resin fumes; destroys optics Teflon / PTFEReleases highly toxic fluorine compounds Any material with unknown compositionIf you don't know what's in it, don't laser it

Testing Methodology

Before running any new material, perform this test sequence:

1. Fire test (small spot): Set low power (10%), short pulse (20ms) on a corner. Observe: Does it char? Melt? Ignite? Produce colored smoke?
2. Line test: Engrave a short line at varying speeds (100, 200, 400, 600 mm/s) at 30% power. Check which speed gives the desired mark depth without excess charring.
3. Power ramp test: Engrave squares at increasing power (10%, 20%, 30%, 40%, 50%). Find the minimum power that produces your desired result.
4. Cut test: Cut a small circle at your estimated settings. If it doesn't cut through, increase power 5% or reduce speed 20% and retry.
5. Document your results: Record the material source, thickness, and optimal settings for future reference.

Factors That Affect Settings

• Lens focal length: A 4" lens produces a larger spot size than a 2" lens — needs higher power or slower speed for the same result
• Lens condition: A dirty or damaged lens reduces effective power by 10-30%. Clean your lens regularly.
• Mirror alignment: Misaligned mirrors reduce power delivery to the work surface
• Air assist: Strong air assist (30+ PSI) allows faster cutting with less charring
• Material temperature: Cold material needs more power; warm material cuts easier
• Moisture content: Wet wood needs more power and produces more steam/smoke
• Batch variation: Even the same material from the same supplier varies between batches

Post-Processing by Material

MaterialPost-ProcessMethod Wood (cut edges)Remove charSand with 220 grit; wipe with mineral spirits Acrylic (cut edges)Polish edgesFlame polish with propane torch (quick pass); or sand 400→600→1000→plastic polish Acrylic (engraved)Fill with paintApply acrylic paint over engraving, wipe excess with damp cloth while wet Glass (engraved)CleanWipe with glass cleaner; no additional processing needed Anodized aluminumSeal (optional)Apply clear coat for outdoor durability LeatherConditionApply leather conditioner or beeswax to engraved areas Rubber stampsMount Glue to wood block; trim excess with knife

Power Compensation by Wattage

If your laser has a different power rating, use these multipliers:

Your Laser PowerRelative to 50WAdjustment 40W (K40)0.80×Reduce speed by ~20% or increase power proportionally 60W1.20×Can increase speed ~15% or reduce power ~15% 80W1.60×Can increase speed ~35% or reduce power ~35% 100W2.00×Can increase speed ~50% or reduce power ~50% 5W diodeN/ACan only engrave most materials; cut very thin wood/paper only 10W diodeN/ACan cut 3mm plywood slowly; engraves well 20W diodeN/ACan cut 6mm plywood; good for engraving darker materials

Note: CO2 and diode lasers have different wavelengths (10.6μm vs 450nm) and interact with materials differently. These tables are for CO2 lasers unless otherwise noted.

🔧 Related tool: Material Settings Lookup