Design Studio: Laser Cutter

Quick Start

2D digital fabrication technique. All files must be .dxf format.
Undergraduate coursework only and approved student groups.
Submit files for cutting. No self-service. TAs manufacture parts for you.
Recommend design consultation with TAs prior to file submission. See TA Office hours.

Stock Materials & Cost Estimation

Most commonly used for soft wood and select plastics.
Maximum material thickness of 1/4″. Work area is ‎24” x 18” (W X H)
Soft wood and acrylic material are always in-stock for thicknesses ranging from 1/8″ to 1/4″.
Other materials may be custom ordered. Here is a full list materials appropriate for laser cutting. Consult with a TA if you want to use these materials.
There is no charge for use of the laser cutter for class projects; however, you may be asked to estimate part costs. Conservatively, assume $0.05 per square inch for wood stock and $0.10 per square inch for plastics.

Design Considerations

The laser cutter can both cut-through material and etch. Cut-through is the default assumption on all .dxf files.
If prescribing etching or engraving, you need to note this on your laser cut request form. You must also manually edit your .dxf file to distinguish cut-through from etching/engraving lines as follows:
- Red = full thickness cuts (RGB 255,0,0)
- Blue = vector engraving (RGB 0,0,255)
- Black = raster (grayscale bitmap) = (RGB 0,0,0)
It is possible to create 3D geometries out of 2D laser cut parts. One more common 3D geometry is an enclosure box. This brief video shows you how to design and manufacture box shapes using the laser cutter.
Laser cutting is a subtractive manufacturing operation and produces a kerf. It is important to consider this kerf in designs that need a particular kind of fit (e.g., press fit, slip fit). Demo boards with different types of fits in common materials are available in The Fab Lab. Also refer to the quick guide below.

All files submitted for laser cutting must be in .dxf format. Follow this video tutorial on how to create a .dxf file easily from SolidWorks.
Once you’re all ready to laser cut, complete the Laser Cutter request form. It will ask you for the following information.
- Information about your project (course, team number, your contact info)
- Choice of material & thickness
- Your .dxf file
A TA will look over your request and will approve or reject your part for processing. The TA will correspond with you on the status of your part.
It generally takes 5-7 days for processing, and your part will be delivered to you as specified by your particular course, e.g., put into your project bin or pick up in designated location.
If you have questions about the status of your order, please contact the TAs via me-laser@udel.edu

If you need assistance with the laser cutter, please email the TA team at me-laser@udel.edu.

Fab Lab TA names and contact information listed below. Fabl Lab TA Office Hours listed here.

Zachary Conroy, Lead TA zconroy@udel.edu

TJ Kaifer, TA tjk@udel.edu

Alex McCarthy, TA alexmc@udel.edu

Nikki Pilla, TA npilla@udel.edu

Dylan Taylor, TA drgrey@udel.edu