FILM LASER

CUTTING & MARKING

Selected plastic films, including PET, polyester, polyimide, and certain polycarbonate, polyamide, polypropylene, and polyethylene films, can be laser cut. Compatibility and edge quality depend on the polymer, thickness, color, additives, coatings, adhesive layers, liner, laser wavelength, and processing settings.

PET or polyester film and polyimide film are common starting materials for laser cutting. The best film depends on the required heat resistance, flexibility, electrical insulation, edge quality, feature size, marking contrast, and layer construction.

Always verify the complete film structure, including coatings, inks, adhesives, backing, release liners, and laminated layers, before processing.

Plastic film laser settings depend on the machine model, laser source, film type, thickness, color, coatings, adhesive layers, focus, air assist, and required result. The following Bolt RF CO₂ settings for polyester film, commonly referred to as Mylar®, are starting references and should be tested on the actual film before production.

These values are intended as starting points only. Always run a small material test and adjust the speed, power, focus, frequency, air assist, DPI, and number of passes according to the actual film and required result.

For settings covering more Thunder Laser models, laser powers, materials, lenses, and processing methods, visit our complete CO₂ laser settings library.

CO₂ lasers are commonly used for through cutting, kiss cutting, perforating, and selected surface processing of compatible polymer films. UV lasers are better suited to fine, low-heat marking and selected micro-processing when reducing melting and thermal deformation is important.

The most suitable laser source depends on the film composition, thickness, absorption, layer structure, feature size, production speed, and required result.

Yes. Compatible PET and polyester film, including suitable Mylar® products, can be cut with a CO₂ laser. Because PET is a thermoplastic, excessive heat may produce fused, glossy, raised, or slightly distorted edges.

Correct focus, faster processing, controlled power, suitable airflow, stable hold-down, and effective extraction can help improve PET film laser cutting results.

Compatible polyimide film, including selected Kapton® grades, can be laser cut, patterned, perforated, and marked. It is commonly used for electrical insulation, thermal barriers, flexible electronics, masks, and precision industrial components.

Adhesive-backed, coated, fluoropolymer-laminated, metallized, or copper-clad polyimide products require separate review because every layer changes the processing and safety requirements.

Selected thin polycarbonate films can be laser cut or marked, but results may include discoloration, melting, residue, or edge deformation. Test the exact film grade, thickness, coating, printing, and flame-retardant formulation before production.

Selected polyethylene and polypropylene films may be laser cut or marked, but their relatively low melting temperatures make them prone to curling, shrinking, raised edges, and localized melting.

Fast processing, controlled heat input, stable film positioning, suitable airflow, and small-scale testing are important for PE and PP film laser cutting.

Metallized PET film may support through cutting, marking, or selective removal of the metallized layer. The result depends on the polymer substrate, metal coating, reflectivity, electrical function, layer thickness, laser wavelength, and required depth.

Treat metallized PET as a multilayer material rather than ordinary PET film, and test the complete structure before production.

Some adhesive-backed films can be laser processed when the film, adhesive, coating, and release liner are all identified and confirmed as laser-compatible. Adhesives may melt, bleed, leave residue, or produce fumes that differ from those generated by the main film.

Always test the complete adhesive film construction rather than evaluating only the surface material.

Laser kiss cutting cuts through the top film and, when required, its adhesive layer while leaving the compatible release liner or lower substrate intact. It is commonly used for labels, gaskets, insulation parts, masks, spacers, overlays, and pressure-sensitive adhesive components.

Accurate kiss cutting requires controlled laser energy, consistent film flatness, and a uniform layer structure.

Compatible multilayer films may be through-cut, kiss-cut, perforated, or selectively processed. Every carrier, coating, adhesive, cover film, backing, and release liner must be identified before processing.

The thickness and laser absorption of each layer determine whether the beam cuts through the full construction or stops at a selected depth.

Yes. Compatible plastic film can be laser perforated or scored to create tear lines, easy-open features, fold guides, ventilation patterns, micro-openings, and controlled partial-depth designs.

The process must be tested carefully to ensure that the laser modifies the intended layer without fully cutting through or excessively weakening the surrounding film.

Use a vacuum work table or a properly configured hold-down method to keep thin film flat and stationary. Block unused suction areas when appropriate and adjust the airflow so that fumes are removed without lifting or moving the film.

Stable positioning helps maintain consistent focus, accurate dimensions, controlled layer penetration, and cleaner cut paths.

Melting, curling, shrinkage, and raised edges are commonly caused by excessive heat input, slow processing speed, unsuitable focus, repeated passes, poor beam absorption, unstable positioning, or a low-melting film formulation.

Reduce heat accumulation and test the speed, power, frequency, focus, number of passes, airflow, and hold-down method.

Yes. PET absorbs different laser wavelengths at different rates. Standard CO₂ systems are widely used for PET film cutting, while selected CO₂ wavelengths and optical configurations may provide different edge or surface results.

UV lasers are commonly selected for fine PET film marking when a small heat-affected area and limited surface deformation are required. The actual film formulation must still be tested.

No. PVC and vinyl films can release toxic and corrosive gases during laser processing, creating serious risks for operators, equipment, and the workspace.

Do not process PVC, vinyl, chlorinated film, unknown halogenated materials, or films whose complete chemical composition cannot be verified. A fume extractor does not make prohibited or unknown materials safe to process.

A laser can process selected polyimide coverlay, insulation film, adhesive layers, and compatible polymer components used in flexible circuits. Copper-clad or multilayer flexible circuits may require camera registration, different laser wavelengths, selective ablation, or hybrid processing.

Do not describe a process simply as flexible PCB cutting unless the exact film, metal, adhesive, and layer construction being processed has been identified.

Yes. Plastic film laser cutting and marking can produce fumes, odors, vapors, smoke, and airborne particles. Use effective source extraction, verify the complete material composition, and actively supervise the machine throughout processing.

For indoor workshops, schools, laboratories, makerspaces, or production areas that require filtration, the Thunder Air Fume Extractor provides dedicated smoke, particle, odor, and VOC filtration for compatible Thunder Laser workflows.

Filtration equipment does not make PVC, vinyl, chlorinated film, or unidentified materials safe for laser processing.

RF CO₂ laser systems are suitable for detailed cutting, kiss cutting, perforating, and small film features. Larger CO₂ laser machines support larger working areas, sheet-film processing, and production batches, while UV laser systems are better suited to fine, low-heat marking on PET and other compatible films.

The best machine depends on the film type, thickness, layer construction, feature size, work area, production volume, positioning requirements, and required result. If the material construction or laser compatibility is uncertain, submit it to the Thunder Laser Material Testing Service for application validation and recommended settings.