In brief, I make a few mods that involve custom plastics. I originally made them by hand, and less than a year ago I purchased a small CNC machine to make them. While much better, it still takes a lot of effort and there is a lot of cleanup each time I make a plastic.

In searching, there are some new home DIY laser engravers/cutters, and I'm curious if anyone can tell me if they would work for my needs? I use .080" PETG sheets which I find are as close to OEM plastics as I can get. I've performed numerous Google searches, YouTube searches, searched through Pinside, contacted makers of the products, etc., but I just can't seem to get a definitive answer on this specific application with thin clear PETG sheets. Maybe I'm missing something obvious, but I'm not finding the information I seek.

I've outsourced large jobs before, but 99% of the time I just need to make a single one-off plastic (I have a handful of different shapes) and my volume is quite low (probably less than 5 per month), so outsourcing really doesn't make sense for me since I don't want to inventory any pre-made plastics given demand is random and slow.

Here is an example of the type of engraver/cutter I'm looking at (5.5W laser): https://www.amazon.com/gp/product/B08QCWGJRN/ref=ox_sc_act_title_2

Here is the material I wish to cut shapes from: https://www.amazon.com/gp/product/B013GOMH0W/ref=ppx_yo_dt_b_search_asin_title

Also, if anyone happens to already own a similar laser system (the same 5.5W laser is ideal) that would be willing to giving things a try, I'd be happy to send some material and shapes for testing purposes.

I've used Lexan in the past but switched to PETG when I learned that's what pinball plastics are made from. The PETG is softer in the same thickness and much easier to work with IMO (plus it is a little less expensive). Both seem durable enough to me. I think in the few years I've been making plastic replacements and accompaniments to my mods, I've only had one of the dozens I've made break (which I replaced at no cost to the customer).

Again, I previously made plastics by hand with pneumatic cutting disks, etc., I then switched to a CNC machine for better accuracy/consistency since I deal with mainly curved shapes, but now I'd really like something that was less of a mess and overall easier to do consistently (the CNC shavings produced are crazy, and I still have to sand and flame treat edges) - i.e. why I'm asking about laser engravers/cutters.

Okay, I'm not quite following the logic. Here is how I'm interpreting the information thus far: The laser in the machine I'm looking at is 445nm and the CO2 laser is 10,600nm wavelength. It's hard to find any definitive answer, but it looks like PET (not G) at around just under 400nm goes to 100% transmittal. Does this mean that any wavelength above 400nm will pass through and cut the the material? The higher the wavelength the easier the laser with pass through?

If this is correct thinking, given that 445nm is only fractionally higher than 400nm (assuming PETG has the same qualities as PET - which it probably doesn't), that it might theoretically cut PETG but it would be so slow in doing so it would deform/burn the material?

I'll have to check that the Makerspace, but probably not very convenient for me as I'm on the West side of Fort Worth (it's about a 45 minute drive w/o traffic from my house). Maybe there's something similar on my side of the Metroplex.

Looks like there are a couple with lasers, but the nearest ones are 45 minutes from me from what I can tell. Also, there are monthly membership fees which I'm not interested in as I wouldn't take advantage of the space very often, and when I did it would be just for quick little things. Good idea though, thanks for the suggestions.

Well, I think I'm coming to the realization that I'll just have to keep using my home CNC machine for now. Disappointing, but seems to be the best/most cost-effective option for small volume DIY.

What got me going on this, however, was a 3D printing video I watched (I can't find it again) and they quickly showed laser cutting thin clear acrylic sheets with brown film on it using what appeared to be a Glowforge or something similar (it was just a close-up shot inside the bed). This is what got me thinking that a DIY laser might very well cut thin sheets of PETG.

Update: Just did some YouTubing and the Glowforge will definitely cut clear acrylic (even thicker than the PETG I use) as long as it has masking on it. However, I researched a little more and the Glowforge uses a CO2 laser at 10,600 nm rated at either 40W or 45W depending on the model. Unfortunately, it's $3K to get into the base model.

I'll have to do a more detailed search when I have some time. I did lookup a couple of libraries, but they don't list what equipment they have.

Looks like an inexpensive K4 CO2 laser cutter is what would do the trick, and those can be had for under $400 before add-ons. The only issue with these is the size. I don't have a shop as my garage is actually used for parking cars, of all things. I just don't have room to permanently setup a machine which is why I was hopeful for the smaller units that I could store away when not in use.

I appreciate everyone's ideas an input to my original post, and hopefully this thread will be useful to those that follow until there is a better solution.

I wanted to put a little closure on my situation regarding the reason I started this thread. At this point, while I really want to buy a K4 laser, I just don't have the room for it. I've scoured the web and made several calls to local maker spaces, and either they don't have a laser, are at least 30-45 minutes away, and/or they require a membership with monthly dues.

Fortunately, I received a referral to a small pinball business in Houston, TX called UpKick Pinball (http://upkickpinball.com), and I contacted the owner. While I'll let him tell you his story, he is a really nice guy with a passion for pinball who just happens to have a CO2 laser. His pricing for clear plastics is very fair/affordable, and within a day of me supplying him the files he had already shipped my order, then a couple of days later they arrived and are perfect - proper size shape, clean cuts, and finished edges.

Therefore, if you are in a similar boat as I am where you need clear plastics cut in small quantities, UpKick is a great alternative to acquiring the tools and knowledge to do it yourself.

Yes, it is a 3018, this one specifically: https://www.amazon.com/gp/product/B07MDG7R2J/ref=ppx_yo_dt_b_search_asin_title

For what it is, it works well. The main issues I have with it with cutting PETG/Acrlic is the mess it makes. I still have to then sand the edges and flame polish them. Also, it takes multiple passes (3 to cut .080" PETG), and I've had occasions where I didn't have everything secured well enough, so I ended up destroying the material and having to start over. Probably the biggest pain when it comes to cutting plastics is that you must use some form of adhesive to secure the plastic to the sacrificial board which in turn is secured to the bed. Not only does it add time and cost to the project, but after cutting the adhesive is difficult to remove from the plastic, then I have to clean the parts with an adhesive removal agent, and finally wash with soap and water.

With a CO2 laser you cut it in one pass, and in many occasions the edges are already finished from the laser cut itself. There are now plastic shavings to deal with, and you don't have to secure the material with adhesive which makes the process much cleaner, easier, and quicker.

Actually need sheets as full contact is required. I've used carpet tape which is sticky as crazy, but it tends to gum up the bits. I then switched to another adhesive sheet I use for decals and while it sticks great, it is so thin it is hard to remove off the plastics (not impossible, just takes time).

https://www.amazon.com/gp/product/B00XZ5VUQK/ref=ppx_yo_dt_b_search_asin_title