LASER CUTTING STYRENE

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There are several things that are different about laser cutting styrene as opposed to many other materials. 

Is it safe to laser cut styrene? 

Safe, yes, but it is a little tricky.  Styrene tends to cut with rolled edges so the thinner the better for clean cuts. You can do better with less power, more speed, and two passes. Another option for straight cuts is to have the laser score it then break out the pieces. 

What about issues with poisonous fumes?

Styrene doesn't contain PVC, so no worries there with fumes. As long as your laser has a full filter system that extracts outdoors, it should not be an issue. However, cutting anything that has chlorine in it like PVC generates chlorine gas, which despite your filtration system, might affect your lungs. The thing with cutting PVC or other plastics with chlorine is that not only is it bad for your lungs, but it is bad for your equipment. It can deteriorate your optics, corrode the metal, and otherwise foul your electronics.

What’s the key to getting a clean cut? 

Avoid thick items like polystyrene (foam). Most table top laser systems have the power but not the focus to cut through an inch of material no matter how soft. The beam starts to spread and you get a ragged cut. The thinness of the material is always the key to a clean cut. 

What effect does too much heat have on the process? 

Watch for the material moving because of the heat. Especially thin parts can literally lift up and turn sideways. Cut it with the fastest speed that gets through it with as much power as it takes. Test… set the speed… then adjust the power till it's through. If you run the laser too hot, it will give you more melted edges. A good rule of thumb for styrene (.5mm, for instance) is to run the laser at about 20% power and 50% speed. Running at 40% power and 100% speed would leave much more obvious melted edges.

What about cleanup? 

Generally there is a bit of cleaning up but not much. A quick once over with some 240 girt wet and dry and then some 400 and it looks fine. The (.5mm) can be a bit harder if you rush it but if you work your way through with multiple cuts there isn't much more in the way of cleaning up to do.

Any cool new ideas learned from cutting styrene?

Cut out letters can be made from plain old foam styrene blue insulation board. It cuts very quickly and cleanly and can then be painted for great looking signs and even glued with Liquid Nail adhesive! 

(P.S. Be sure and use latex paint because oil based paints like Krylon and Rustoleum will melt the letters.)