LASER FOCUS

FEATURE NAMEENGRAVING BY AUTHORBY ASHLEY BRAY

How laser machines can expand your capabilities and bottom line.

If sign shops are looking to bring in a machine that offers a multitude of capabilities, then they should look no further than a laser engraver/cutter.

“A laser engraver or cutter is a smart addition to any sign shop,” says David

Stevens, industrial applications manager,

Trotec Laser, Inc. “Not only can they make current sign-making processes more efficient, but [this hardware] can also allow shops to expand their product offerings by branching into other markets.”

According to Anthony Harris, US manager of Applications and Government Sales for Gravotech, Inc., laser machines offer “enhanced workflow, expanded product capabilities, and improved productivity.”

Harris gives the example of cutting acrylic out for decorations, logos, etc. With a router, a shop will have to go back and polish the edges. But a laser machine eliminates this step since it creates a flame-polished edge.

Lasers can also help on the installation side by allowing users to pre-drill holes for standoffs or mounting equipment ahead of time as well as create mounting templates. “As you’re cutting out your lettering, cut it on the second surface and then laser in recesses where you’re going to put your epoxy to mount your stand-offs. Now you’ve got the exact location for your standoffs,” says Harris, who says a sheet of paper or poster board can then be put into the laser. “Then have the laser cut where those standoff recesses were in your lettering. You now have a template that you

can tape on the wall.

“It can take a wall lettering job in a lobby from a half-day installation down to an hour.”

Purchasing Considerations When considering which laser machine to buy, wattage is one of the biggest factors, which is closely related to material thickness. “The desired cutting depth will need to be considered when choosing a wattage for the laser system—the thicker the material, the more power you will need,” says Stevens.

Harris notes that 80-watt laser machines are the most common buy for sign shops. “They want to purchase the most wattage they can afford based on their application,” he says. “[Take, for example,] a sign shop that buys a 60-watt laser instead for cutting half-inch acrylic. The 60-watt laser is going to cut the half-inch acrylic, but the 80-watt laser is going to do it faster. And you have more margin for error in your settings. You don’t have to have it dialed in as perfectly as you would the 60-watt.”

Production volume can also be a factor when choosing a machine. This can require a bit of future projection if you’re looking to grow with your laser machine. Adam Voigt, Marketing & Sales for Kern Laser, says, “Consider where your company wants to end up and if you have the right customers lined up for that.”

Also think about the machine’s working area or bed size. “With a larger working area, you can not only process larger sheets of material, but you can also process bigger batches in one job,” says Stevens.

According to Harris, the most common laser size they see in the average sign shop is 24-by-24 inches. “Get the largest laser that your space allows and that your application requires,” he says.

Harris notes, however, that if you only need a larger bed for a few projects a year, it may be better to outsource those jobs and opt for the smaller laser that frees up space on the shop floor. “Space is a concern for a lot of people,” he says. “Square footage costs dollars.”

A final, but important factor is the type of material sign shops will want to process. Acrylic is the most common. “Lasers and plastics go super well together,” says Voigt.

But there are additional substrates to consider like wood, leather, laminates, foam, and other plastics. “The materials will determine whether or not you will need a CO2, fiber, or dual source laser,” says Stevens. “CO2 lasers can process a wide variety of materials including acrylic, plastic, wood, textiles, paper, and many other substrates. Fiber lasers are made for marking on metals and plastics, while a dual source laser combines both CO2 and fiber laser sources.”

Some materials are not recommended for use on a laser machine, like PVC. “It potentially can be hazardous to the operator if your exhausting isn’t adequate, but it also leaves an acidic residue inside the laser and the exhaust system that is going to damage the laser,” says Harris.

Stevens cautions sign shops to be aware of PVC being present in other materials, such as vinyl. “We recommend finding laser-safe vinyl materials that do not contain PVC,” he says. “Other materials you want to avoid or approach with caution are chromium, carbon fibers, PVB, PTFE/Teflon, beryllium oxide, and any materials containing halogens.”

Harris says to be careful processing high-end decorative panels and substrates that use recycled materials because these may include substances that aren’t laser friendly or won’t be cut cleanly by the laser. Always check safety data sheets before processing to be sure the components of a material are truly laser friendly.

Marking Your Opportunities Laser machines also open sign shops up to a wide range of opportunities. “From promotional products to trophies and awards to general customization and personalization applications, there are endless opportunities,” says Stevens.

Harris notes that lasers are great for the textile market since they sear the edges so that the fabric doesn’t unravel.

The gift and personalization market is also a good consideration for shops, especially for marking on items like stainless steel tumblers. “Metal is also a popular material, particularly coated or stainless steel tumblers, which can be a very lucrative application that is easily and efficiently engraved or marked with a laser,” says Stevens. “Sign shops should note that

a marking compound will be required when using a CO2 laser.”

Harris adds that laser machines can be used in combination with lit signage to better distribute the light. “Take some cast acrylic and laser in a grid system on the back of that cast acrylic,” he says. “Now if you edge light that on two sides, everywhere that the laser marked the acrylic casts off light, so it gives you a more uniform light dispersion through the acrylic over the surface of the entire print.”

The onset of COVID-19 has also led many shops to pivot and find opportunities making PPE and acrylic barriers with their lasers. “While COVID-19 has had negative impacts on many lives and businesses, it has also opened up new opportunities for businesses to shift their focus,” says Stevens. “We have had many customers use their lasers to create face masks, face shields, and other PPE items, as well as using them to create COVID-specific signage. Hand washing or face mask signage, social distancing signs, and acrylic barriers for cashiers and businesses have become extremely popular items that can easily be created with a laser system.”

Harris also sees lucrative opportunities in fabricating decorative panels to separate tables and booths in restaurants.

Voigt recommends sign shops pay attention to their local customers and look to fulfill any needs that may pop up. For example, he notes a client that pivoted to cutting 1/8-inch-thick acrylic guards to protect bus drivers.

Refining Your Skills Voigt recommends that shops spend time testing and experimenting with their laser machine. “Since it is so versatile, my general advice would be to get uncomfortable with your laser system,” he says. “Get uncomfortable with different materials because most of them are going to be applicable to different industries.”

Meanwhile Trotec has pivoted its inperson workshops to a virtual platform, which has allowed more people to participate. “Virtual workshops and Webinars are an excellent opportunity to refine your skills or to learn new processing tips and techniques, especially in the current environment,” says Stevens. “We always offer a live Q&A session, which allows people to get answers to their questions in real time, as well as connect with other laser users.”