Week 3: Computer-Controlled Cutting – Group Assignment Documentation


1. Assignment Objective

The objective of this group assignment is to characterize the laser cutter's cutting and engraving parameters for various materials available in the lab. We aimed to determine the optimal values for:

  1. 1. Power
  2. 2. Speed
  3. 3. Frequency
  4. 4. Kerf (material loss during cutting)

2. Materials and Tools Used

Equipment Model / Type Notes
Laser Cutter Epilog / GCC / Trotec (Lab-specific) CO₂ Laser
Materials 3 mm MDF, 3 mm Acrylic Used for parameter testing
Software Inkscape / Rhino / Fusion 360 Design software
Laser Control Software RDWorks / JobControl / LightBurn For parameter setting and file transfer

3. Group Task Overview

As a team, we performed the following:


4. Machine Setup ,Calibration and Safety precautions


Machine Overview — SIL9060 Laser Cutter

The SIL9060 is an industrial grade CO₂ laser cutting and engraving machine designed for high-precision work across materials such as wood, acrylic, MDF, leather, paper, and textiles. With a spacious 900 × 600 mm working area and a powerful sealed glass CO₂ laser tube, it offers accurate cutting and engraving performance for educational, industrial, and prototyping applications.

SIL9060 Laser Cutter machine

Key Features

  1. 1. Industrial grade CO₂ laser cutting and engraving system
  2. 2. Spacious 900 × 600 mm working area suitable for medium-sized projects
  3. 3. Supports multiple file formats such as DXF, AI, PLT, BMP, JPG, and PNG
  4. 4. Adjustable power levels (typically 60W, 80W, or 100W)
  5. 5. Water-cooled CO₂ sealed glass laser tube for consistent performance
  6. 6. Equipped with a red-dot pointer for accurate job alignment
  7. 7. Exhaust and ventilation system for smoke and fume extraction
  8. 8. Offline USB control capability for easy workflow integration

Technical Specifications

Specification Details
Work Area 900 × 600 mm
Laser Power 60 W / 80 W / 100 W (depending on configuration)
Laser Type CO₂ Sealed Glass Tube
Cooling Method Water Cooling
Cutting Speed Up to ~48,000 mm/min
Engraving Speed Up to ~64,000 mm/min
Positioning Accuracy < 0.025 mm (in some versions)
Supported File Formats DXF, AI, PLT, BMP, JPG, PNG
Typical Materials Wood, MDF, Acrylic, Leather, Paper, Fabric, etc.
Operating Voltage AC 230V ± 10%

Key Advantages & Considerations

  • Large working area enables versatile material processing for Fab Lab projects.
  • Compatible with multiple file formats and CAD tools (AutoCAD, Fusion 360, etc.).
  • High cutting and engraving precision suitable for press-fit and design experiments.
  • Requires proper air assist, ventilation, and cooling maintenance for safe operation.
  • Ensure the nozzle focus distance (≈8 mm) for optimal cutting results.

Reference Links

4.1 Focus Adjustment

  • Focused the laser head using the focusing gauge for accurate distance between lens and material.
  • Correct focusing ensures precision for both engraving and cutting.
SIL9060 Laser Cutter machine

4.2 Origin and Alignment

  • Set the origin point (X, Y, Z) manually from the machine panel.
  • Checked the material alignment using the bed grid for straight cuts.
SIL9060 Laser Cutter machine

4.3 Air Assist and Exhaust

  • Air assist enabled to prevent burning and achieve clean edges.
  • Exhaust system turned on for smoke removal and better visibility.
SIL9060 Laser Cutter machine

4.4 Cooling System

  • Cooling system turned on to maintain a stable temperature.
  • Water flow checked to ensure proper heat dissipation.
SIL9060 Laser Cutter machine

SIL9060 Laser Cutter machine

4.5 Emergency Stop

  • Emergency stop button pressed to immediately halt the laser cutting process.
  • Button functionality tested to ensure prompt response in case of emergency.
SIL9060 Laser Cutter machine


5. Kerf Measurement

5.1 Procedure

  • Designing a 100 mm × 100 mm square using the optimal parameters.


    • Verneir caliper measurements

    Using LaserCAD software for sending the design to the Laser machine

    Verneir caliper measurements

    Cutting Designed files for measurement

    Verneir caliper measurements

    Verneir caliper measurements

    Measuring the Files for the Kerf Measurement in both MDF and Acrylic materials

    Verneir caliper measurements

    Verneir caliper measurements

    Verneir caliper measurements

    Verneir caliper measurements

  • Measured slot width using a vernier caliper.
  • Measured both cut piece and remaining slot using a vernier caliper.
  • Calculated kerf = (slot width – piece width) / 2.

    • 5.2 Results

    Material Designed Size Measured Slot (mm) Measured Piece (mm) Kerf (mm)
    MDF 100 × 100 100.30 99.70 0.30
    Acrylic 100 × 100 100.25 99.75 0.25

    6. Safety Measures

    • Always wear protective glasses during operation.
    • Never open the laser lid while cutting.
    • Keep the exhaust and air assist active.
    • Do not cut PVC or unknown plastics (toxic fumes).
    • Check material flatness and lens focus before starting each job.

    7. Computer Controlled Cutting - Power vs Speed Test

    We tested how laser cutting power and speed impact the cutting and engraving quality when adjusted relative to each other.

    The experiment was conducted using two different materials: 2 mm MDF board and 2 mm Acrylic sheet.

    7.1 2D Design in Fusion 360

    For the 2D design, we used Fusion 360.

    • Created a new sketch and drew one rectangle with set dimensions.
    • Used the Rectangular Pattern option to create 4 rows and 4 columns.
    • Added text using the Text Tool to label each box with power and speed percentages.
    Fusion 360 Sketch Example

    After completing the design, it was exported in DXF format for laser cutting.

    Fusion 360 DXF Export Image

    7.2 Importing into LaserCAD

    The DXF file was imported into the LaserCAD software.

    • Different colours were used to distinguish cutting, engraving, and non-operation paths.
    • The rectangle boxes were assigned for cutting and the text areas for engraving.
    LaserCAD Import Interface

    7.3 Cutting Process

    • Set the origin of the nozzle to the required start position.
    • Checked the workspace boundaries to ensure enough space for cutting.
    • Closed the safety door and ensured the exhaust was turned ON to remove burnt gases.
    • Finally, started the laser machine and ensured both laser and exhaust systems were functioning properly.
    Laser Cutting Process

    Laser Cutting Process

    7.4 MDF (3 mm) Test Results

    Test No Power (%) Speed (%) Frequency (Hz) Result Remarks
    1 50 100 500 Not Cut Power too low
    2 60 60 1000 Partial Cut Slight burn
    3 70 40 1000 Perfect Cut Optimal
    4 80 30 1000 Burnt Edge Excess power

    Optimal Setting: Power = 70%, Speed = 40%, Frequency = 1000 Hz

    7.5 Acrylic (3 mm) Test Results

    Test No Power (%) Speed (%) Frequency (Hz) Result Remarks
    1 40 80 500 Engraved Only Low Power
    2 50 60 1000 Partial Cut Not Through
    3 60 40 1000 Perfect Cut Clean Edge
    4 70 30 1000 Melting Excess Power

    Optimal Setting: Power = 60%, Speed = 40%, Frequency = 1000 Hz


    8. Summary

    Through this group activity, we learned to:

    9. Design and Test Patterns

    9.1 Test File

    A test file was designed consisting of:

    • 1. Multiple squares and circles to test kerf and fit.
    • 2. Gradient text for engraving power variation.
    • 3. Parameter labels (speed, power) for reference.

    File Format Used: .DXF / .SVG

    Kerf Test.dxf
    Power Test.dxf