How to Troubleshoot Common Laser Cutting Issues: A Guide

LaserOMTech Updated On April 03, 2025

Photo credit to @sadas on Lightburn Forum

Is your laser machine leaving some parts of your material uncut? Are certain areas cutting well while others fall short? You're not the only one dealing with this! Many laser cutting enthusiasts face these problems, especially when working with challenging materials like plywood. Let’s break down the most common causes and walk through the steps to fix them so your cuts are clean and consistent.

Identifying the Issue

Few things are more frustrating than a laser cutter that works flawlessly in one spot and barely cuts in another. This is a frequent issue when working with plywood and similar layered materials. While it’s easy to assume the machine is to blame, inconsistencies in cutting often come down to material or setup—not necessarily the laser itself.

Why Material Quality Matters

The performance of your laser cutter depends heavily on the material you're using. Inexpensive plywood can be particularly difficult due to its internal makeup:

Uneven Density: Layers in plywood may include glue, filler, or knots that absorb laser energy differently.
Unknown Fillers: Lower-grade plywood often includes hidden substances that interfere with cutting.
Tough Adhesives: The glue between layers may be resistant to lasers, especially in inconsistent patches.

Fine-Tuning Your Laser Settings

Improving your cut quality often starts with adjusting your machine’s settings:

Enable Constant Power: This setting helps your laser maintain the same intensity throughout the cut, especially around corners where speeds usually dip.
Set Power Correctly: For diode lasers, aim for around 97.5% power and ensure both minimum and maximum values are equal for uniform output.
Use Multiple Passes: Rather than maxing out power and reducing speed—which may cause scorching—try doing several lighter passes for cleaner edges.
Check Your Focus: Make sure your laser is correctly focused on the material surface. Even small errors in focus can cause major cutting inconsistencies.

How to Choose Better Materials For Your Laser Cutting Projects

If adjusting your settings doesn't help, your material may be the root of the issue:

Laser-Compatible Plywood: Some plywood is specifically manufactured for laser work and will have fewer imperfections.
MDF with Maple Veneer: For CO₂ laser users, this is a popular and reliable option that cuts cleanly with minimal defects.
Invest in Quality: It may be tempting to save money with cheaper sheets, but better materials often save time and reduce waste.

Advanced Troubleshooting Techniques

When your work demands precision, try these expert-level approaches:

Minimum Power Adjustment: On CO₂ machines, lowering the minimum power helps avoid overburning on corners while still completing the cut.
Do Test Runs: Always test a new material or design in a small area before committing to a full project.
Map Problem Spots: Take a close look at your sheet before starting to identify visible inconsistencies and plan your cuts accordingly.

Limitations of Diode Lasers

While diode lasers are an excellent option for beginners, especially for engraving or light cutting, they do have drawbacks:

Lower Cutting Strength: Diode lasers generally struggle with thicker or denser materials.
More Sensitive to Inconsistencies: Any variation in the material is more likely to affect the cutting quality.
Slower Workflow: Because they lack raw power, diode lasers often require multiple passes, making jobs take longer.

Why Upgrade to a CO₂ Laser?

For users who are ready to scale up or tackle more demanding materials, a CO₂ laser cutter is a smart investment:

More Cutting Power: CO₂ machines can easily handle thicker woods, acrylics, and other dense materials.
Faster Production: Increased power translates to quicker cuts and higher throughput.
Versatile Materials: You’ll be able to engrave and cut a wider variety of materials including leather, glass, and plastics.
Consistent Results: CO₂ lasers are better equipped to manage the inconsistencies found in common sheet goods like plywood.

Final Thoughts

Laser cutting challenges are part of the learning curve—but with the right techniques, materials, and equipment, great results are within reach. The key is to understand how different variables affect your outcome, from the material’s density to the machine’s focus and settings.

If you're ready to improve the quality and reliability of your work, consider switching to a CO₂ laser engraver. OMTech offers a wide variety of machines built for everyone—from weekend crafters to full-time business owners. Known for their power, reliability, and accessible pricing, OMTech’s laser cutters are a top choice for anyone looking to level up their creative or commercial projects.

Visit OMTech today to browse their full lineup of CO₂ laser machines and find the right tool to match your needs. Don’t let cutting issues slow you down—upgrade your setup and unlock the full potential of laser cutting.