What Materials Can (and Can’t) Be Cut with a CO₂ Laser
A practical, safety-first guide for anyone using — or considering — a laser cutter.
Just Because It Fits in the Machine, Doesn’t Mean It Should Be Cut
CO₂ laser cutters are incredibly versatile machines. They can cut, engrave, and mark a huge range of materials with speed and precision — which is exactly why they’re so popular in workshops, schools, and small manufacturing environments.
But with that versatility comes responsibility.
One of the most important things any laser owner needs to understand is this: not all materials are safe to cut with a CO₂ laser. Some materials simply won’t cut well. Others can damage the machine. And a small number are genuinely dangerous to people and equipment.
This article is designed to give you a clear, practical understanding of what can be cut safely, what shouldn’t be cut at all, and why those distinctions matter.
Materials That Are Safe to Cut with a CO₂ Laser
Wood and Wood-Based Materials
Natural wood, MDF, plywood, and veneered boards are some of the most commonly used materials with CO₂ laser cutters. A laser cuts wood accurately and consistently, making it ideal for signage, decorative panels, models, prototypes, and detailed artwork. Wood-based materials are often a natural starting point for new laser users because they’re versatile, readily available, and respond well to the laser process.
That said, different wood products behave very differently. MDF cuts very cleanly and predictably, but it produces a large amount of fine dust and strong fumes, so effective extraction is essential. Plywood quality varies significantly depending on the type of glue used between layers — some sheets cut cleanly, while others char heavily or struggle to cut through evenly. For this reason, plywood sold as “laser-grade” is usually worth considering, as it’s designed specifically for consistent laser cutting.
Some edge darkening on wood is normal when using a laser cutter. With the correct balance of speed, power, focus height, and air assist, charring can be minimised, resulting in clean, professional-looking edges that often require little to no finishing.
Acrylic (PMMA)
Acrylic is one of the best materials to work with on a CO₂ laser and is often considered the benchmark for laser cutting quality. It cuts cleanly and accurately, producing smooth, polished, flame-like edges that usually require no additional finishing. This makes it especially popular for signage, display work, lettering, panels, and decorative components.
Both cast and extruded acrylic can be cut successfully, but they behave slightly differently. Cast acrylic tends to engrave more cleanly and consistently, while extruded acrylic often cuts a little faster. Clear, coloured, mirrored, and fluorescent acrylics all work well with a CO₂ laser, although mirrored acrylic should always be cut from the reverse side to protect the reflective surface.
Acrylic does produce strong fumes during cutting, so good extraction is essential for both safety and cut quality. When the machine is correctly set up with effective ventilation and air assist, acrylic is a safe and very rewarding material to laser cut.
Leather (Vegetable-Tanned Only)
Natural, vegetable-tanned leather can be cut and engraved very effectively with a CO₂ laser, producing clean edges and detailed markings. It’s commonly used for labels, patches, book covers, branding elements, and decorative items, and responds well to both cutting and engraving when the settings are correctly dialled in.
However, not all leather is safe to laser. Many commercially available leathers are chrome-tanned or chemically treated, and these processes can release harmful fumes when exposed to laser heat. The risks aren’t always obvious by appearance alone, which makes leather one of the materials that requires extra caution.
If you’re unsure how a piece of leather has been processed, it’s safest not to cut it. Always check with the supplier where possible, and only laser materials that are clearly specified as vegetable-tanned and laser-safe.
Paper, Card, and Cardboard
Paper and card cut extremely easily with a CO₂ laser, which makes them ideal for packaging prototypes, templates, stencils, modelling, and craft work. The laser allows for very fine detail and clean edges, making it possible to produce intricate designs quickly and accurately.
Because paper-based materials are highly flammable, extra care is required when cutting them. Correct power and speed settings, continuous airflow, and effective extraction all help reduce the risk of flare-ups. While the fire risk is low when everything is set up properly, paper and card should always be cut under supervision and never left unattended during operation.
Why Extraction and Air Assist Matter So Much
Even when cutting safe materials, fumes and particulates are part of laser cutting. Proper extraction removes smoke, improves cut quality, protects optics, and keeps the workspace safe.
Air assist helps by:
- reducing flare-ups
- keeping lenses clean
- improving edge quality
- preventing charring
Poor extraction and dirty optics are often blamed for bad cutting results — when the real issue is airflow, not power.
Materials That Should NEVER Be Cut with a CO₂ Laser
PVC and Vinyl (Including Faux Leather and Some Foams)
PVC is the most dangerous material to laser cut.
When cut, it releases chlorine gas, which is extremely harmful to humans and corrosive to machines. Even small amounts can damage optics, rails, electronics, and extraction systems — and pose a serious health risk.
If a material smells strongly of chlorine, plastic swimming pools, or harsh chemicals when heated — stop immediately.
This includes:
- PVC Sheets
- Vinyl
- Some synthetic leathers
- Some foams
- Banner material
If you are unsure whether a plastic contains PVC, do not cut it.
ABS Plastic
ABS plastic does not cut cleanly with a CO₂ laser and is generally unsuitable for laser cutting. Instead of vaporising cleanly, ABS tends to melt and burn, producing thick, sticky fumes that can coat lenses, mirrors, and internal components. This residue is difficult to remove and can quickly degrade optical performance.
The cutting result is usually poor, with melted edges, heavy discolouration, and an unpleasant smell. For both quality and machine-protection reasons, ABS should be avoided entirely when using a CO₂ laser.
Polycarbonate (Lexan)
Polycarbonate is often mistaken for acrylic, but it behaves very differently when exposed to a CO₂ laser. Instead of cutting cleanly, polycarbonate tends to discolour and char heavily, producing dark, rough edges and an inconsistent finish. The material absorbs heat rather than vaporising cleanly, which leads to poor cut quality and excessive burning.
Even in thin sheets, polycarbonate cuts badly and produces unpleasant fumes. For these reasons, it is not suitable for CO₂ laser cutting and is best avoided entirely in favour of laser-friendly alternatives such as acrylic.
Fibreglass, Carbon Fibre, and Epoxy-Based Composites
Materials such as fibreglass, carbon fibre, and epoxy-based composites release hazardous fumes and fine airborne fibres when exposed to a CO₂ laser. These fibres are dangerous to inhale and can cause serious irritation and long-term health issues if proper controls are not in place.
In addition to the health risks, these materials can damage laser machines by contaminating optics, extraction systems, and internal components. For both safety and equipment protection reasons, fibreglass, carbon fibre, and similar composite materials should never be cut with a CO₂ laser.
How to Check If a Material Is Safe
If you’re ever unsure whether a material is safe to laser cut, it’s important not to guess. Taking a few minutes to check can prevent serious health risks and costly damage to your machine. Start by reviewing the supplier’s datasheet or looking up the material’s chemical composition so you know exactly what it contains.
If uncertainty remains, a small test can be carried out outside the machine using controlled heat — never inside the laser cutter itself. Any material that produces strong, unusual, or chemical-smelling fumes should be avoided. When there is any doubt at all, the safest option is simply not to cut it.
A laser cutter is a powerful and precise tool, but it should never be used as a chemistry experiment.
Final Thoughts From the Workshop Floor
CO₂ laser cutters are incredibly capable machines — but their safety depends entirely on what you put inside them.
Understanding which materials are safe protects:
- your health
- your machine
- your optics
- your extraction system
- your workshop
The best laser users aren’t just skilled — they’re informed. And knowing what not to cut is just as important as knowing what cuts beautifully.
A clean cut starts with the right material — and the right knowledge.