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How can you improve CAD designs for polycarbonate laser cutting?

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Polycarbonate is a versatile and durable material that can be used for various product design applications, such as protective cases, lenses, and displays. However, cutting polycarbonate with a laser can be challenging, as it can produce uneven edges, discoloration, and toxic fumes. To avoid these problems, you need to improve your CAD designs for polycarbonate laser cutting. In this article, you will learn some tips and best practices to optimize your CAD files and achieve better results.

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David Castillo, MEng - MASRR

Dise?ador CAD | Profesor de Cátedra | Creador de Contenido

1 Choose the right laser type

Not all lasers are suitable for cutting polycarbonate, as some can cause excessive melting, burning, or cracking. The most recommended laser type for polycarbonate is a CO2 laser, which has a wavelength of 10.6 micrometers and can cut through the material with minimal heat and damage. A CO2 laser can also produce a smooth and clean edge, as well as a clear and transparent cut. However, you need to adjust the power, speed, and frequency of the laser according to the thickness and shape of your polycarbonate piece.

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2 Use vector graphics

Vector graphics are ideal for creating CAD designs for polycarbonate laser cutting, as they can define the shape and outline of your design with precise and scalable lines and curves. Vector graphics can also reduce the file size and complexity of your CAD file, which can improve the performance and accuracy of the laser cutter. You can use software tools like Adobe Illustrator, CorelDRAW, or Inkscape to create and edit vector graphics for your polycarbonate design. You can also convert raster images to vector graphics using online converters or plugins.

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Ahmad Wazzan

Product Design/3DExperience
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Vector graphics are ideal for creating CAD designs for polycarbonate laser cutting because they define shapes and lines using mathematical equations, allowing for precise and scalable representation of the design. Unlike raster images, which are made of pixels and can lose quality when scaled, vector graphics maintain their clarity and sharpness at any scale. In the context of laser cutting, the laser cutting head requires a vector path to follow, and only vector graphics with the smallest possible line thickness, or 'hairline' width, will be cut by the laser. This ensures accuracy and consistency in the cutting process.

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3 Avoid sharp corners and small details

Sharp corners and small details can cause stress and deformation on your polycarbonate piece, as the laser can overheat or burn the material at these points. To prevent this, you should avoid creating sharp corners and small details in your CAD design, and instead use rounded or chamfered edges and larger features. This can also improve the aesthetics and functionality of your polycarbonate product, as it can reduce the risk of cracking, chipping, or breaking. You can use software tools like Fusion 360, SketchUp, or SolidWorks to modify and smooth your CAD design.

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David Castillo, MEng - MASRR

Dise?ador CAD | Profesor de Cátedra | Creador de Contenido
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A diferencia del corte en placa metalica, el policarbonato tiende a agrietarse mas facilmente cuando se hace el termoformado, o el dobles por calentamiento, asi que no se pueden aplicar los mismo principios de cierres de esquina y desahogo, en policarbonato hay que hacer cortes rectos o pronunciados y no peque?os alivios de dobles, ademas al ser plastico es mas complicado doblar el policarbonato.

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4 Add kerf compensation

Kerf is the width of the material that is removed by the laser during the cutting process. Kerf can affect the dimensions and accuracy of your polycarbonate piece, as it can create gaps or overlaps between the parts. To compensate for the kerf, you need to add a small amount of extra material to your CAD design, depending on the thickness and type of your polycarbonate and the power and speed of your laser. You can use software tools like AutoCAD, Rhino, or LaserCut to calculate and add kerf compensation to your CAD design.

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5 Ventilate and clean

One of the main challenges of cutting polycarbonate with a laser is that it can produce toxic fumes and smoke, which can harm your health and the quality of your product. To avoid this, you need to ventilate your workspace and use an exhaust system or a fume extractor to remove the fumes and smoke from the laser cutter. You also need to clean your polycarbonate piece after cutting, as it can have dust, debris, or residue on the surface. You can use a soft cloth, water, and mild soap to wipe and rinse your polycarbonate piece.

By following these tips and best practices, you can improve your CAD designs for polycarbonate laser cutting and create high-quality and professional products. Polycarbonate is a great material for product design, as it offers strength, flexibility, and transparency. However, you need to prepare and optimize your CAD files for the laser cutting process, as it can pose some challenges and risks. With the right laser type, vector graphics, edge design, kerf compensation, and ventilation and cleaning, you can overcome these challenges and achieve better results.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you improve CAD designs for polycarbonate laser cutting?

1

2

3

4

5

6

1 Choose the right laser type

2 Use vector graphics

3 Avoid sharp corners and small details

4 Add kerf compensation

5 Ventilate and clean

6 Here’s what else to consider

Product Design

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How can you improve CAD designs for polycarbonate laser cutting?

1

2

3

4

5

6

1 Choose the right laser type

2 Use vector graphics

3 Avoid sharp corners and small details

4 Add kerf compensation

5 Ventilate and clean

6 Here’s what else to consider

Product Design

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感谢您的反馈

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