Top Ten Ways to Reduce Laser Cutting Costs – Tip #9

Material Thickness

How flexible are you on material choice for your design? To cut out a shape, the laser is burning through the material. Different materials burn at different rates, and also the thinner a material is, the faster it will cut. For example, 4mm cardboard cuts very quickly, and 9mm acrylic cuts very slowly.

Choosing the right material can reduce laser cutting costs considerably. If your design allows for it, create prototypes in paper (Tip #2) or cardboard (Tip #3) before moving on to thicker or harder materials. You can then have greater confidence in a successful outcome once you move up to the premium materials for your final design.

Have you had experience where changing the material thickness helped reduce laser cutting costs? Let us know in the comments below.

For more complex designs or projects that have a larger vision behind them, it’s time for Tip #10: Ponoko Prime.

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #8

Line vs Area Engraving

For creating surface details on your design, consider using Line Engraving. This method involves the laser following a defined shape, whereas Area Engraving (which can be much more time consuming) is similar to how an inkjet printer works, with the laser head passing across the sheet many times horizontally until the area has been completely filled. Both Area and Line Engraving have their merits, but it is almost always cheaper to use Line Engraving simply because less machine time is required.

There may be times where your design demands the use of Area Engraving. If this is the case, keeping the engraved parts as close together on the template as possible will help to reduce costs.

How have you saved on laser cutting costs by changing your approach to laser engraving? Let us know in the comments below.

Next up we discover whether size matters with Tip #9: Material thickness.

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7 Tips for Sucessful Selling this Father’s Day

Our top 7 tips for those selling their wares this Father’s Day

I can hear my dad now: “When I was your age, we didn’t start our Father’s day campaigns until June!”. Ah, dad how things have changed.

Father’s day is June 21, and if you’ve selling your Ponoko-made goods online, you’ll want to start planing now. Here are our top seven tips to share your men’s wares with those buying Father’s Day gifts.

1. Reach Out

Folks who have bought from you in the past are more likely to buy from you again. They are already familiar with your products and right now they’re scratching their heads trying to figure out what to get their old man, so let them know! Send out an email with an update on your newest products, and any specials you’re running for Father’s day.

2. Get in Gear

Planning ahead is essential if you want to make sure your products get up in front of your customers in time. You can start marketing right before Mother’s Day and carry your efforts through to Dad’s Day itself. Use our Guaranteed Order Deadlines for Father’s Day as a starting point and work backwards to ensure you’ve got everything ready and in stock when the orders start rolling in.

3. Be Inclusive

Don’t forget all of the different dads out there – The grandads, step-dads, first-time dads, households with two dads, god fathers and father figures. Don’t limit your potential sales to just one kind of relationship.

4. Add a Dad

If visitors are quickly scanning over your shop, they won’t notice that an item is a great Father’s Day gift unless it’s immediately obvious. Getting a dad in your product photo is a great way to visually hint that your product will make a great Father’s day gift. You don’t even have to use your own father – any roommate, spouse, or co-worker than can pass as a dad will do the job.

5. See What Folks are Looking for

Google’s search suggestion feature (shown above) is a quick and easy way to see what folks are looking for this Father’s day. Use the auto-complete function to gather intelligence on search terms like “father’s day gifts” & “gifts for dad”. Do a quick search for “father’s day gift guide” to see what’s popular in your particular niche.

6. Change it Up for Dad

Changing a color scheme from pinks and yellows to blues, grays, or blacks can put a masculine touch on a product. You can also explore swapping out materials like leather or wood. Those gold acrylic stud earrings? Boom, now they are manly wooden cufflinks. You can also put a spin on your items by adding sports or gaming elements.

7. Group Dad Items Together

As you can see in tip #5 above, “father’s day baskets” are a hot search right now. You don’t have to put your products in a literal basket, but grouping together a few complimentary items like a gift & a laser cut greeting card will help. You’re giving your customers an opportunity to save some time with a more impressive looking gift – and you can boost your sales in the process.

Use these notes, as well as our Guaranteed Order Deadlines for Father’s Day as a jumping-off point to create an attention-grabbing campaign around Father’s Day. Feel free to share your big plans below!

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #7

Pieces close together

With the knowledge that you’re paying for every move the laser makes, keeping all the pieces of your design close together can really make a difference. Instead of having them scattered around the template, try to fit them all together (kind of like a jigsaw puzzle).

Depending on your design, it may even be possible for some pieces to share a cutting line. Just be sure you don’t forget about removing double lines as we saw in Tip #6 if there are any overlaps.

When pieces are close together or sharing a cutting line, be sure that you leave enough space for the kerf (how much material the laser burns away – see here or here).

Once you have tested (and tested and tested!) your design on the P1 template and are ready to produce multiple copies, clever use of the larger P3 template will further reduce the cost per item.

Have you tried grouping parts together in your own laser cutting? What impact did it have for you? Let us know in the comments below.

Now that we have our layout sorted, let’s move on from outlines to details with  Tip #8: Vector vs Raster engraving.

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #6

Avoid Double Lines

When objects are positioned side-by-side, a double cutting line can result if there is an overlap. This means that the laser will cut the same section twice – which means you’ll pay double as well! To stop this from happening, take a moment to go through your design file and make sure that there are no shared lines or overlaps.

For more about avoiding double lines and how to fix them, the Ponoko Making Guides provide all the info you need. You’ll find comprehensive Starter Kits for Adobe Illustrator, Inkscape, CorelDRAW and AutoCAD.

Remember that with laser cutting, you are paying for every move the laser makes. Don’t pay twice – check your design file before you upload.

Have you been caught out by this in the past? Let us know your story in the comments below…

Next up we look at another way to keep laser cutting costs down with Tip #7: Pieces close together.

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #5

Simplify details

We already know that it’s helpful to keep things small in size at the beginning. One key aspect that is often overlooked is to keep details simple as well.

This means sticking to designs that take up as little ‘laser time’ as possible.

So how do you go about optimising your design with this in mind? The short version is that the less time it takes to cut, the less it will cost. You’re paying for every movement the laser cutter makes; whether it is cutting, engraving or travelling between cutting and engraving. Many small detailed forms take longer to trace out than fewer larger forms. Circles take longer than straight lines. Items spread out or are further apart take longer to cut than items located close together.

Dense vector line engraving also comes with the same warning. Remember that with lasers, time really does equal money.

What impact has keeping details simple had on your laser cutting costs? Let us know in the comments below.

The next handy hint focuses on another way to save time, and therefore cost, with your laser cutting. Stay tuned for Tip #6: Avoid Double Lines

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #4


Start small

A great tip for first timers and also just as useful for more experienced makers is to keep things small and simple at the beginning. In short, stick to the Ponoko P1 template. Starting small enables you to test your ideas and be confident before charging ahead with multiple items on larger sheet sizes.

This will keep material costs lower, which is handy not only when experimenting with laser cutting for the first time but also if you are trying out a new material that you haven’t used before.

Make the most of the P1 template size by performing small tests of multiple design ideas. Don’t assume your first attempt will be “The One”. Try multiple cuts, shapes, engravings, etc to see what you like the look of. You are much more likely to end up with a design you are happy with if you remind yourself that it’s not about getting that perfect outcome on the first try.

Keep in mind that with laser cutting, more size or complexity means greater costs. So the smaller dimensions of the P1 template help to constrain the amount of making time, which again means both cutting and material costs will be lower.

What savings have you made by starting small with your laser cutting? Let us know in the details below.

Stay tuned for the next handy piece of advice from the Ponoko team. It’s time to pare things back with Tip #5: Simplify details.

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #3

Make a Cardboard Version First

It is an exciting moment when your design is ready to be laser cut, but it can really pay off to do a trial cut in cardboard first before moving ahead with more expensive materials.

Remember, with laser cutting you are paying for the time it takes for the machine to make your design… and cardboard cuts really quickly. This contributes to it being one of the most affordable materials, which means you can get a fast, inexpensive test run of your design. Once you are happy with the cardboard version, you can order your design in a more expensive material with greater confidence that it will come out the way you had hoped.

If your final outcome is to be made from cardboard… well, then kick back and relax because you’re already one step ahead!

Tell us about how trial cuts in cardboard have helped keep your laser cutting costs down in the comments below.

Next up in the Top 10 Ways to Reduce Laser Cutting Costs is a handy bit of advice that is easy to overlook. Tip #4: Start small

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Top Ten Ways to Reduce Laser Cutting Costs – Tip #2

Paper Prototypes From Your Home Printer

Even if you are positive that your design is just right, it is always wise to check those details one more time before sending files to be laser cut. There is a very simple way that this can be done, thanks to your trusty desktop paper printer.

Printing out your design on paper is an ideal way to spot sizing or design errors, see whether holes or tolerances are big enough, and get a general feel for what your final result will look like. You could consider this as a free instant first prototype.

Working with digital files can be super efficient but sometimes people do lose track of whether their design will look just as good in the physical world as it does on-screen. So start your physical prototyping at home, and confirm that everything is a-ok before spending time and money on laser cutting. Once you have your details sorted, then take the plunge and upload your files to Ponoko for laser cutting.

Have you saved by making paper prototypes at home? Tell us about it in the comments below.

The next in our 10 rules for keeping laser cutting costs down is an extension of the paper prototype, but this time the lasers are firing. Stay tuned for Tip #3: Cardboard before expensive materials.

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How To Make Glue-less Interlocking Parts

Using the SketchUp plugin SliceModeler for the best friction fit

There are several ways to create 3D shapes from flat laser cut material, and each have their merits. Many Ponoko users ask questions about how to best design for interlocking parts – making this one of the more popular choices for transforming laser cut forms into 3D objects.

Interlocking parts can be mechanically fastened together, but in this tutorial we are looking at how to design friction-fit connections that neatly snap and lock into place.

Pictured above is a laser cut trivet made by Ponoko user Andrew Jones. To produce this form he used the freely available software SketchUp along with the handy SliceModeler plugin. He then compiled a detailed Instructables walkthrough that outlines his design process for interlocking laser cut products.

To achieve the glue-less design, small curved bumps (nodes) are added into each slot. This extra material allows the parts to slide together with enough contact and pressure to fit snugly. This sounds easy enough, but just how to get the right size and number of nodes takes some time and patience. Slot length, material thickness and density are just a few of the factors that need to be considered.

I highly recommend creating parts with different size and numbers of nodes so you can find the best fit that works for you. You might want a very hard fit that needs to be tapped together with a rubber mallet or you might want a fit that can be assembled by hand without any tools. The only way to find the fit that works for you is try different size nodes.

Click through to the full tutorial where you will learn how to create a basic form using Sketchup and SliceModeler, add the nodes, export into Inkscape and then add the final SVG to a Ponoko template ready for laser cutting.

via Andrew Jones on Instructables

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