What is Fiber Laser Engraving?

Fiber laser engraving is a laser engraving process that uses a fiber laser to etch or mark designs onto materials. It is a relatively new technology that entered the manufacturing scene in the 1990s and has rapidly grown in popularity due to its precision, speed, and versatility compared to traditional laser engraving methods.

Fiber lasers differ from conventional laser engraving machines in that they utilize a glass fiber doped with rare-earth elements as the lasing medium to generate the laser beam, rather than CO2 gas, crystal, or semiconductor diode lasers. This allows fiber lasers to generate laser beams with infrared light at very focused wavelengths and high beam quality, making them ideal for engraving intricate details and small characters.

During fiber laser engraving, artwork or vector line paths are imported into laser engraving software, which controls the movements of the fiber laser. The laser rapidly pulses on and off as it traces over the paths, essentially vaporizing microscopic pieces of the material's surface to etch away material. Fiber laser engravers can mark metals, plastics, wood, leather, glass, rubber, and more with permanent marks ranging from fine detailed etchings to deep impressions.

Compared to older laser engraving methods, fiber laser engraving machines offer many benefits:

• Higher precision for marking very intricate patterns with fine details. The focused beam allows fiber lasers to mark areas as small as 0.01mm.

• Faster engraving speeds.

• Can mark highly reflective metals like aluminum, brass, silver and copper without special coatings.

• Produces clean etchings with little roughness or raised edges around markings.

• Lower power consumption than CO2 lasers.

• Minimal setup, training and maintenance required compared to traditional lasers.

• Compact footprint to fit into small workshops or offices.

Due to these advantages, fiber laser engravers have found wide use for marking logos, serial numbers, barcodes, labels, and more across industries including manufacturing, product customization, prototyping, jewelry, sign making, and craft businesses. They enable high quality engraving with precision, speed and flexibility unmatched by previous technologies.

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Fiber Laser Engraving Machines

Fiber laser engraving machines utilize a high-powered fiber laser to precisely engrave or mark materials. They consist of several major components:

• Laser module: This contains the fiber laser source, which emits the high intensity beam used for engraving. Fiber lasers are capable of outputting anywhere from 10 to 100 watts of power.

• Motion system: The motion system, comprised of stepper motors and galvo scanners, controls the movement of the laser head and allows the beam to trace patterns across the work surface. Most affordable machines use stepper motors while professional machines use faster galvo scanners.

• Chiller: The laser module needs to be cooled, usually with a water chiller, due to the heat generated. Chillers regulate the temperature of the cooling water.

• Exhaust system: Fumes and debris need to be extracted, so an exhaust fan and filter system is used. Some systems recirculate filtered air back into the workspace.

• Computer and software: Software like LightBurn or LaserGRBL controls the laser based on designs loaded from a computer. Most fiber laser machines accept vector graphic files.

Fiber laser engravers are available in a variety of configurations:

• Small desktop machines are suited for hobbyists or light engraving work. They have lower power lasers and smaller work areas.

• Mid-size benchtop machines offer more laser power and larger work areas while still fitting on a tabletop. This allows for faster and higher resolution engraving.

• Large format machines are high-end, with the most power and largest work areas. They can engrave very large objects.

When selecting a fiber laser engraver, consider the size of objects you'll be engraving, desired engraving speed and precision, budget, and safety requirements. Higher power professional machines produce faster and finer results but require more precautions.

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Materials You Can Engrave

Fiber laser engravers can mark a wide variety of materials, including metals, plastics, wood, leather, glass, and more. The most commonly engraved materials are:

Metals

Metals are very compatible with fiber laser engraving due to their high level of laser energy absorption. Common metals used are:

• Aluminum - One of the most popular metals for laser engraving. Creates a matte finish when engraved.

• Stainless Steel - A durable metal that can be engraved to create a high contrast mark.

• Anodized Aluminum - Creates a light mark when the anodized coating is removed.

• Brass - Engraves easily with great contrast depending on the finish.

• Titanium - More challenging to engrave but can create very dark marks.

Plastics/Polymers

Many common plastics and polymers can be successfully laser engraved:

• Acrylic - A transparent plastic that creates a frosted look when engraved.

• ABS - Most commonly used for injection molded plastic parts.

• Polycarbonate - A very strong plastic often used for transparent structures.

• Wood Filled Polymers - Mixed with wood for an engraved effect.

Other Materials

Additional materials that can be marked with a fiber laser include:

• Wood - Creates a nice dark mark on natural wood. Engrave at lower power.

• Leather - Fiber laser removes the top finish layer. May require masking/prep.

• Glass - Ceramic materials like glass require high power density.

• Rubber - Care must be taken with flammable materials.

Nearly any material compatible with other CO2 or YAG lasers can also be processed with fiber laser engravers with the right settings. Always test unfamiliar materials at low power first.

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Software for Fiber Laser Engraving

Fiber laser engravers require digital design files to function. There are a few software options for designing and preparing files:

Design Software

• Adobe Illustrator - Industry standard vector design software. Great for creating vector shapes, text and layouts to engrave.

• Inkscape - Free open source vector software. Similar capabilities as Illustrator.

• CAD Programs - Software like Fusion 360, AutoCAD, SolidWorks etc can output DXF files that work for laser engraving.

• Photoshop - Raster image editing software. Can be used to prepare jpeg, png, etc images for engraving.

File Formats

Common file formats for laser engraving include:

• Vector Formats - EPS, AI, DXF, SVG. Vector shapes do not lose quality at any size. Ideal for engraving.

• Raster Formats - JPEG, PNG, GIF. Made up of pixels. Resolution dependent.

Most laser software can import both vector and raster formats. Vector is preferred for sharp, clean engravings.

Sending Designs

There are a few ways to get design files to the laser:

• USB Drive - Load files directly onto a USB drive and plug into the laser. Simple transfer.

• Ethernet Cable - Connect the laser directly to your computer with an ethernet cable for file transfer. Fast and reliable.

• Laser Software - Most laser systems have engraving software to manage file transfer and settings. Easy to import files and engrave.

• Print Driver - The laser will have a virtual print driver to print files directly from design software. Convenient option.

Overall, laser engraving requires digital design skills and vector/raster knowledge. But file transfer to the machine is straightforward with various connectivity options.

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Design and Layout Basics

When designing artwork for laser engraving, there are some important considerations to keep in mind:

• Focus on high contrast designs. The laser will engrave lighter areas deeper than darker areas. So using black and white artwork with strong contrasts will give you the best results. Avoid shades of gray as they will not engrave as distinctly.

• Use vector graphics whenever possible. Vector file types like AI and EPS can be resized without loss of quality. This allows you to scale to fit different material sizes perfectly. Raster images like JPG and PNG will lose clarity if resized significantly.

• Keep important elements away from edges. You'll get the cleanest engraving by keeping text and graphics at least 1/4 inch inside your material edges. The laser can sometimes leave rough edges on the sides.

• Maximize your engraving area. Take advantage of the full engraving bed size of your laser when laying out your artwork. Nest multiple elements close together to fit more onto each piece. But leave at least 1/4 inch between separate engravings.

• Add registration marks if doing double-sided engraving. Registration marks, such as crosshairs or circles, ensure alignment between sides. Put a mark in each corner when engraving the first side. Then line these up when flipping the material to engrave the back side.

• Consider how you'll post process the material. Will you be painting? Adding a clear coat? Sanding or polishing after engraving? Your design choices should account for how the laser engraved finished product will look.

Thinking ahead and optimizing your artwork for laser engraving will result in professional, crisp results every time. Taking the laser bed size, layout spacing, contrasts, and post processing into account will help your designs engrave as intended.

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Laser Settings and Techniques

One of the keys to successful laser engraving is understanding how to properly configure the laser settings. The main settings to pay attention to are:

• Speed - This determines how fast the laser moves while engraving. Slower speeds allow the laser to impart more energy into the material, allowing for deeper engraving. Faster speeds result in lighter engraving.

• Power - The laser power setting controls how much energy is delivered to the material. Higher power settings engraves deeper but can also increase heat and the risk of fire and damage to the material. Lower power is good for annealing and surface marking.

• Frequency - The laser pulses on and off rapidly during engraving. The frequency setting controls how fast it pulses. Lower frequencies allow more heat dissipation while higher frequencies can help limit excess heating on sensitive materials.

• Focus - Proper laser focus is critical for good engraving quality. The focus needs to be set precisely at the surface of the material being engraved. Improper focus will result in poor detail and excess heating.

Raster vs Vector Engraving - Raster engraving scans the laser back and forth across an area, like scanning a photocopier. This allows shading and textures. Vector engraving follows a path outline, which is better for sharp lines and details.

Annealing - Annealing involves re-heating metals after laser engraving to relieve internal stresses. This helps prevent oxidation and improves durability of engraved metal surfaces. Use low power raster passes to evenly anneal the metal after engraving.

Dialing in the right settings takes practice and testing. Engrave samples on scrap materials to find the ideal combination of speed, power, frequency, and focus for your engraving needs.

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Safety

When working with a laser engraver, there are some important safety precautions to take.

Eye Protection

• Always wear safety goggles when operating or observing the laser. The laser beam can damage unprotected eyes.

• Use goggles that are designed for laser applications, with optical density of 5 or higher. Regular safety glasses do not provide adequate protection.

• Make sure there are no gaps between the safety goggles and your face that would allow the laser beam to leak through.

Ventilation

• Laser engraving can produce smoke and fumes that need to be ventilated properly.

• Use an exhaust fan or ventilation system to remove smoke/fumes from the laser work area.

• Vent the exhaust outside or through a filter system designed for laser exhaust. Do not vent indoors or into occupied spaces.

Fire Prevention

• Some materials are flammable when engraved by a laser. Always check material safety before engraving.

• Have a fire extinguisher on hand in case a fire starts while laser engraving. A CO2 extinguisher is recommended.

• Never operate the laser unattended. Stay near the machine while it is running.

Handling Chemicals

• Certain materials require chemical post-processing that can be hazardous. Use proper protective equipment.

• Work in a well-ventilated area when using solvents and chemicals.

• Read safety data sheets and follow all chemical handling precautions.

• Properly dispose of used solvents/chemicals. Do not pour down drains.

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Post Processing

After engraving your work, you'll want to complete some post processing to make the finished piece really shine. This may include cleaning, polishing, applying coatings, and filling engraved areas.

Cleaning and Polishing

Once your engraving is complete, wipe away any debris or residue from the laser engraving process. You can use a soft cloth or cotton swabs dampened with water or isopropyl alcohol. Be gentle so you don't scratch the surface.

For metal surfaces like stainless steel or aluminum, you can also polish the engraved areas to make them reflective and smooth. Use increasingly fine grit sandpaper to buff out any oxidation or discoloration. Finish with a polishing compound on a buffing wheel or muslin wheel to make metal surfaces gleam.

Coatings

Consider applying a clear coat finish to wood, acrylic or other engraved materials. This will protect the surface from scratches, fading, and wear over time. Options include polyurethane, lacquer, epoxy resin or a UV-cured acrylic coating. Spray or brush on 2-3 thin coats for best results.

Filling Engraved Areas

To provide contrast and emphasize engraving depth, you can fill the recessed areas with paint, epoxy, colored enamel, India ink, or other media. For shallow engraving, rubbed with colored pencil lead or chalk can provide subtle, softer infill. Clean the surface first so fill material adheres properly. Remove any excess material from the top surface with a plastic card or razor blade.

With some careful post processing, your engraving can look clean, crisp and professionally finished.

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Advanced Techniques

Fiber laser engravers allow for some advanced techniques that can take your engravings to the next level. Here are some of the most popular advanced engraving techniques:

Color Fills

Color fills allow you to add color into the engraved areas of your workpiece. This is done by filling the engraved areas with an acrylic paint or epoxy resin. The paint or resin will remain in the engraved areas while the surface can be wiped clean. This results in a engraving with vivid colors.

Some guidelines for color filling:

• Choose paints or resins designed for laser engraving so they properly bond to the engraved areas.
• Clean the surface thoroughly before applying the paint or resin.
• Apply the paint thickly over the engraving, allowing it to pool in the recessed areas.
• Let the paint dry per the manufacturer recommendations.
• Once dry, wipe off the excess paint from the surface using a soft cloth. The paint in the engraved areas will remain.

Color fills work on metals like stainless steel, aluminum, and brass. It can also be done on materials like wood and leather. Experiment with different color combinations to create custom works.

3D/Relief Engraving

3D relief engraving involves making multiple passes over an area at different depths to create a raised 3D effect. The laser essentially sculpts the material, lowering the surface unevenly to shape a 3D design.

Relief engraving requires a bit of trial and error to master:

• Design the image in layers, each representing a different depth level.
• Assign each layer a laser speed and power setting to match the depth.
• Engrave the deepest layer first, then each higher layer after that.
• Some materials like wood and acrylic work best for 3D relief engraving. Avoid brittle materials that will fracture easily.
• Minor undercuts in the design help strengthen overhanging structures.
• Applying a filler or paint after engraving can help highlight the 3D effect.

With some practice, you can create stunning 3D works.

Rotary Engraving

Rotary engraving involves engraving on a cylindrical object as it rotates. This allows you to wrap artwork around cups, glasses, and other rounded surfaces.

Specialized rotary attachments are needed for most laser engravers. The attachment holds the cylindrical object in place and rotates it while the laser head moves parallel to the axis.

Tips for effective rotary engraving:

• Design artwork to wrap continuously around the cylinder.
• Secure cylindrical objects well in the rotary attachment to prevent any wobble.
• Set the origin point of the laser at the center axis of the cylinder.
• Run tests to find the optimal rotation speed and laser settings.
• Focus on materials like plastic, wood, and aluminum that work well for rotary engraving. Glass and crystal can fracture easily.

With some learning and experimentation, you can create custom engraved drinkware, decor pieces, and more. The possibilities are endless!

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Getting Started

Getting started with fiber laser engraving requires some initial preparation and investment. Here are some tips for those just beginning with this technology:

Selecting a Starter Machine

When first starting out, opt for an affordable desktop or benchtop fiber laser machine. Higher wattages provide faster and deeper engraving, but 25-40 watts is sufficient for most hobbyists and small businesses. Ensure the work area and Z height match your anticipated projects. Seek a trustworthy brand that offers service and support.

Essential Supplies

Beyond the machine itself, you'll need materials to engrave, fume extraction, and software. Quality fiber laser materials include metals like stainless steel, titanium, brass, and aluminum. Anodized aluminum creates vibrant marks. Start with a sample pack to test different surfaces. Proper fume extraction is vital - research dedicated laser systems with built-in filters.

Training Resources

Take advantage of free educational content to learn the basics. Video sites have tutorials on operating fiber lasers safely and effectively. Check forums and groups to connect with other users and ask questions. Practice engraving on scrap materials to dial in settings and techniques before moving to real projects.

Finding Projects and Customers

Start engraving custom gifts for family and friends to build skills and test ideas. Offer local businesses personalized promotional items like engraved pens or pet tags. Set up an online shop with customized products. Attend craft fairs and markets to demonstrate your laser. Offer discounts to generate reviews and referrals. Use hashtags and groups to market sample work on social media.