Cutting Vinyl with Laser Cutter | Laser Cut Vinyl Techniques, Tips

If you’re considering creating vinyl stickers or decals, for your own use or to sell, choosing the right machine to create them is important. Laser cutters are super versatile, but is cutting vinyl with laser a possibility? Our experts at OMTech Laser have put together this quick guide to help you understand when you can laser cut vinyl and when you can’t. 

Can You Cut Vinyl with a Laser Cutter? 

It’s possible to laser cut some types of vinyl, but you need to be very careful. Many types of vinyl contain chlorine (polyvinyl chloride or hydrogen chloride), which releases toxic fumes when exposed to a laser. 

These fumes can not only damage your laser cutter, but they can harm you or anyone else nearby. If you’re looking for a vinyl material specifically, double-check that you’re getting a laser-safe vinyl (non-PVC vinyl) before trying to run it through a laser cutter. Otherwise, consider acrylic or PETG instead. 

Laser Cutter Basics 

The laser cutter works by directing the laser beam through mirrors to concentrate the energy on a specific point. This high-energy point (the tip of the laser) heats the material to the point of melting or vaporization. The process is controlled by a computer, allowing for intricate designs and patterns to be cut with practically no material waste. 

Vector Cutting vs. Raster Engraving 

Vector cutting and raster engraving are two distinct methods used in laser cutting. Vector cutting follows a continuous path, defined by lines and curves in a design file, and is typically used for cutting through materials like vinyl. It’s ideal for creating outlines or cutting out shapes, as it cuts all the way through the vinyl. 

Raster engraving, on the other hand, works like a printer, where the laser moves back and forth across the material, burning away the surface without cutting all the way through, to create detailed images or patterns. Raster engraving is used for detailed work, like etching designs or text onto the surface of vinyl. 

Laser Cutter Types for Vinyl 

Which laser cutter is best for cutting vinyl? Let’s compare the three different types: CO2 laser cutters, diode laser cutters, and fiber laser cutters. 

Be aware that using a laser on vinyl requires caution, as vinyl emits harmful chlorine gas when cut. This gas poses health risks, it must not be inhaled, and it can damage the equipment. Consequently, a proper ventilation system is necessary when using laser cutters for vinyl cutting. 

CO2 Laser Cutters 

CO2 laser cutters, like OMTech’s collection here, are the most used type for cutting vinyl. They generate a laser beam through a gas mixture, usually carbon dioxide (hence the name). These lasers are powerful and efficient for cutting a variety of materials, including fairly thick vinyl, thanks to their ability to produce precise cuts with smooth edges. 

Diode Lasers 

Diode lasers are compact and versatile but generally less powerful than CO2 lasers. They are often used for engraving rather than cutting, as their lower power output makes them a bit less effective for cleanly cutting through thicker vinyl materials. You may need to make several passes before it cuts through. 

Diode lasers are more suitable for thin vinyl sheets or surface engraving. They’re a good choice for small projects or hobbyists due to their affordability and ease of use, but they may struggle with precision and speed compared to more powerful laser types. 

Fiber Lasers 

Fiber lasers are highly efficient and precise. They generate a laser beam through optical fibers and offer high-speed cutting capabilities. 

However, they’re mostly used for cutting metals rather than vinyl. Their wavelength is generally not well absorbed by non-metallic materials. Using a fiber laser on vinyl could result in poor cutting quality and potential damage to the material. 

Tips for Laser Cutting Vinyl 

If you do want to laser vinyl and you’ve made sure the vinyl is suitable for laser cutting, follow these tips to do it as effectively and as safely as possible! 

Ventilate the Space 

Laser cutting vinyl can release some harmful chlorine fumes into the air, because of the PVC content in the material. Set up an exhaust system or another ventilation system to make sure the fumes get directed away, preferably outside. An air filtration system could be a good idea too. 

Wear Protective Gear 

Wear appropriate personal protective equipment (PPE), like masks and safety goggles, to minimize exposure to any residual particles. These are a good idea even if you’re using a small machine, because you can’t be too careful. 

Prep the Vinyl Surface 

Before cutting, make sure the vinyl is clean and free of dust or debris. Contaminants can interfere with the laser’s precision and ruin your design. Place the vinyl flat on the laser bed, making sure there are no wrinkles or bubbles. You might also consider using a low-tack adhesive mat to keep the vinyl in place during the process, preventing any unwanted movement that could distort the design. 

Set Your Laser Machine Up Properly 

Vinyl requires specific settings on your laser cutter for optimal results. Usually, a low-power setting with a moderate speed works best to prevent burning or melting the material. Do test cuts on scrap vinyl to fine-tune your settings. The laser should cut through the vinyl cleanly without leaving scorched edges. 

Weed Carefully 

Weeding (which happens after cutting) involves carefully removing the excess vinyl that isn’t part of the design. Use a weeding tool if your design is very intricate, and work slowly to avoid tearing the vinyl. 

Cutting Vinyl with Laser Cutter | FAQs 

Which Laser Cutters Are Good for Cutting Vinyl? 

If you’re planning on creating small vinyl stickers or decals, you can get handy desktop models, like the Polar 350 50w Desktop Laser Engraver. This can cut through non-PVC vinyl up to 0.4 inches thick. 

For thicker vinyl, we recommend something like the Pronto 40 80W CO2 Laser Engraver and Cutter. It’s an excellent choice for bigger vinyl projects and can churn out much higher volumes as well. 

Are Vinyl Cutters or Laser Cutters Better for Cutting Vinyl? 

Vinyl cutters are specifically designed for cutting vinyl. They use a sharp blade to trace designs on the vinyl, making them ideal for intricate patterns and letters. Vinyl cutters are also safer for this material, as they avoid the risk of burning or melting the vinyl.

Laser cutters, on the other hand, are more versatile and can cut a wide range of materials, including acrylic, wood, and fabric. However, when it comes to vinyl, laser cutters may present challenges. The high heat generated can cause vinyl to melt or produce harmful fumes, requiring special ventilation systems. 

Vinyl cutters are better suited for cutting non-PVC vinyl, but you might consider a laser cutter if you’re planning on doing projects using other materials too. 

How Do I Prevent Vinyl from Warping When Using a Laser Cutter? 

To prevent warping, use lower power settings, faster cutting speeds, and consider placing a sacrificial layer underneath the vinyl to absorb excess heat.