Laser Cutting (CO2)

CO2 laser cutting produces precise 2D profiles in thin-to-medium sheet materials with a fine kerf, clean edges, and good speed for intricate geometries.

Overview

CO2 laser cutting uses a gas laser beam focused through optics to cut sheet material with a narrow kerf and minimal mechanical force. It excels at thin-to-medium gauge metals and many non-metals, producing accurate 2D profiles, small features, and clean edges with little or no secondary deburring. Programming is quick, so it supports both prototypes and production runs.

Use CO2 laser cutting for flat parts with intricate contours, tight nests, and moderate tolerance requirements where thermal input is acceptable. Expect excellent edge quality on steels and aluminum up to moderate thickness, with the flexibility to also process plastics and wood on the same machine. Tradeoffs: cutting thicker plate is slower, heat-affected zones can matter for some alloys, and through-thickness tolerances or precision 3D features still require follow-on forming or machining. CO2 is a strong choice when you need a flexible, general-purpose laser for varied materials and consistent, repeatable cuts in sheet stock.

Common Materials

  • Mild steel
  • Stainless steel 304
  • Stainless steel 316
  • Aluminum 5052
  • Aluminum 6061
  • Acrylic sheet

Tolerances

±0.002"–±0.005" on contour features, depending on thickness and part size

Applications

  • Electrical enclosure panels
  • Machine brackets and mounting plates
  • Control panel faceplates and bezels
  • Decorative and architectural panels
  • Ventilation grilles and louvers
  • Signage letters and logo profiles

When to Choose Laser Cutting (CO2)

Choose CO2 laser cutting for flat sheet parts with detailed 2D geometry, moderate thickness, and tight nesting requirements where a small kerf and good edge finish matter. It suits prototypes through production when you need fast programming, low fixturing cost, and the ability to process both metals and non-metal sheets on the same platform.

vs Laser Cutting (Fiber)

Pick CO2 laser cutting when you need a general-purpose laser that can handle both metals and non-metals like acrylic and wood on the same system. For thin-to-medium gauge metals, CO2 still delivers good edge quality and flexibility, especially in shops already tooled for CO2 where your material mix isn’t dominated by high-speed thin-metal production.

vs Plasma Cutting

Choose CO2 laser cutting over plasma when you need finer details, narrower kerf, and cleaner edges in thin-to-medium sheet. It is better suited for intricate profiles, tight nesting, and parts that should go directly to forming or assembly with minimal grinding or secondary edge cleanup.

vs Waterjet Cutting

Select CO2 laser cutting instead of waterjet when thermal effects are acceptable and you want lower cost per part and faster cutting on thin metals. It is ideal where you don’t need cold-cutting or extreme material versatility, but do need high throughput for common sheet metals and some non-metals.

vs Shearing

Use CO2 laser cutting rather than shearing when your parts need internal cutouts, contours, or non-straight edges that a shear cannot produce. It avoids custom tooling, handles complex nested profiles from standard sheets, and supports design changes through simple program updates instead of new dies.

Design Considerations

  • Keep minimum slot widths and web features at least 1–1.5x the expected kerf width to avoid weak features and incomplete cuts
  • Specify realistic tolerances; reserve tighter than ±0.005" only for critical features to avoid extra setup, inspection, and cutting time
  • Use standard sheet thicknesses and materials that shops commonly stock to improve lead time and reduce material cost
  • Design parts for efficient nesting on standard sheet sizes, and allow small common-line cuts between parts where possible to save material
  • Avoid very small isolated tabs, sharp internal corners, and dense micro-features, which slow cutting and can cause heat buildup or part tip-up
  • Clearly call out any cosmetic or edge-finish-critical faces so the shop can orient nesting and choose cutting parameters appropriately