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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Guaranteed Order Deadline for Maker Faire


Hey there makers. If you’ve got something big planned for this year’s Maker Faire Bay Area, these are the dates you’ll need to get your goodies in time for the big event:

Laser Cutting Order Deadlines:
Standard Making & Shipping Speeds: Last Orders by Thursday April 30th 2015.
Upgraded Making & Shipping Speeds: Last Orders by Wednesday, May 13th, 2015.

Metal Machining (PCM) Order Deadline:
Standard Making & Shipping Speeds: Last Orders by Wednesday April 22nd 2015.

3D Printing Order Deadline:
Standard Making & Shipping Speeds: Last Orders by Friday, April 17th 2015.

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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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Guaranteed Order Deadlines for Father’s Day

Ensure delivery in time for Father’s Day day by ordering before these deadlines.

To ensure you’re stocked up in time to sell and ship your products into your customer’s hands, here are your order dates for you to run an organized ship – keep in mind, the earlier you order, the more you’ll save.

Laser Cutting Order Deadlines:
Standard Making & Shipping Speeds: Last Orders by Wednesday June 3rd, 2015.
Upgraded Making & Shipping Speeds: Last Orders by Wednesday, June 17th, 2015.

Metal Machining (PCM) Order Deadline:
Standard Making & Shipping Speeds: Last Orders by Wednesday May 27th 2015.

3D Printing Order Deadline:
Standard Making & Shipping Speeds: Last Orders by Friday, May 22nd 2015.

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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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New Homepage Launched

Announcing version one of our new homepage.

We’ve given the front page of our site a facelift, with the goal of providing newcomers an easier way of learning about who we are and what we do.

This is version one: Next we’ll be unveiling a new & improved materials catalog and an updated Ponoko showroom.

If you haven’t already, take a moment to check out our new home page. We would love it if you took a moment to share your thoughts. What works? What needs improvement? What are you hoping to see in version two? Let us know in the comments below.

Thanks!

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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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Ponoko Customer Blasts Past Kickstarter Goal in 3 hours

Another Kickstarter success using Ponoko

UPDATE: The Electric Eel Wheel has now raised over $40,928! Huge congrats to Maurice & Emily on reaching over 800% of their goal!

Maurice Ribble is the Boston based engineer behind the Electric Eel Wheel – a clever electric spinning wheel that makes it easy to spin the fiber of your choice into yarn.

Maurice’s Kickstarter campaign blew past it’s $5,000 goal in just three hours – and is on track to break $20,000 in under a week.

The Electric Eel Wheel was already a huge hit in the hobby fiber, spinning, and knitting communities, so it made sense to make the jump to Kickstarter. “I figured this would be a good project for it because nothing like it has been done before” Maurice says, ”my wife who’s been helping with this project really liked the idea of doing a Kickstarter so that’s what really decided it for me.”

Traditionally, yarn is spun with a foot powered spinning wheel – a time consuming process that tends to be hard to master. While there are electric alternatives available, quality wheels are costly- with price tags of $800 or more. This gap in the market was part of the inspiration for the Electric Eel Wheel.

Using laser cut parts from Ponoko, Maurice and his wife Emily set out to create their own electric spinning wheel that was affordable, while still being as good or better than the ones currently on the market.

Maurice says using Ponoko made it easy to reduce costs by iterating through different designs. “I was surprised at how much spending some time optimizing the part layout cut my costs.” he says  ”For me it almost cut my costs by half because I was able to share a lot of edges and use the materials more efficiently.”

While this is the fourth commercially available version of the wheel, Maurice was still able to find ways to improve the design and add new innovative features:

“Once I get my hand on the laser cut Ponoko pieces I assemble it and I almost always get ideas on how I might improve it during assembly. When those improvements are getting small I know I’m at the stage where it’s good enough.”

Maurice credits the research he did, as well as the feedback he got early on as the key to Electric Eel Wheel’s explosive success. “I read a lot about how to launch a Kickstarter campaign. Making a good video is important so I spent a lot of time on that.” Maurice says, “I shared it with a few close friends to build my confidence and get feedback on what I might tweak.”

When we asked Maurice what advice he would give to people just starting out with Kickstarter, he warned entrepreneurs-to-be not to let expansion or addition of new features hurt your project:

“Don’t let feature creep hurt your project. First you need to decide when it’s good enough to put on Kickstarter. Some of the ideas that come in are good and I do leave my options open, but you need to always consider pros and cons before adding something.”

Want to get your hands on your own Electric Eel wheel and start spinning your own yarn? The Electric Eel Wheel is available through Kickstarter at a discounted price, with packages ranging from $149-$209.

Got a great hardware idea of your own? Make and sell it with Ponoko.

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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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