It is important to understand the advantages and disadvantages of each technology if you are a business that manufactures plastics, including custom fabrication and high-volume injection molding. This guide will examine and compare the two laser etching systems (carbon dioxide and fiber), their capabilities, the types of materials they can etch, applications in which they can be utilized, and their comparative costs, so you are ready to make an informed decision when selecting a marking solution for your next job.
What is Laser Etching?
Laser etching is an extremely precise and popular non-contact marking process for engraving text, serial numbers, barcodes, logos, and other designs onto almost any substrate. Laser etching utilizes a highly concentrated beam of light to remove or alter the surface level of a material, without changing the structure of the material itself.
Laser etching is particularly useful in custom plastic fabrication because of its:
- Precision
- Permanenc
- Speed
- Compatible with various materials
The two most common types of laser etching systems in plastic manufacturing and industrial fabrication are the carbon dioxide (CO2) laser and fiber laser.
CO2 Laser Etching: Overview
What is It?
A carbon dioxide or CO2 laser is a gas laser that generates a powerful beam of infrared light using a gas-filled tube. CO2 laser engraver systems are typically 10.6 micrometers in wavelength, which makes them especially well suited to organic materials, such as:
- Acrylic
- Wood
- Leather
- Glass
- Paper
- Some plastics (ABS, PMMA, HDPE)
Benefits of CO2 laser etching
- Good for plastic fabrication: CO2 lasers are a good option for acrylic, polycarbonate, HDPE, and PVC, providing a good option for tooling easy-to-source materials in injection molded and custom fabricated applications.
- Great detail on organic materials: They are particularly effective at etching clean logos or text on materials like acrylic sheets for signage or retail display applications.
Also, CO2 systems usually come in larger bed sizes, providing larger working areas for larger format plastic panels or mass production runs.
Disadvantages of CO2 lasers
- Slower on metals: CO2 lasers are not a good option for marking metals unless coated or anodized.
- Less beam intensity: CO2 lasers normally need more power and slower speeds to mark deeper when processing hard materials.
- More consumption and maintenance; replacing the gas-filled tube in the laser system requires more ongoing costs.
Fiber laser etching: Overview
What is it?
Fiber lasers work by taking optical fibers that have been doped with rare earth elements to create a wavelength of approximately 1.06 micrometers. This shorter wavelength creates a much higher intensity beam, which lends itself to marking:
- Metals (stainless steel, aluminum, copper)
- Dark colour plastics
- High-performance polymers
- Ceramics
Benefits of fiber laser etching
- Best choice for marking metal components: Fiber lasers are the industry standard for direct marking of metal, and indispensable in the production of automotive parts, medical manufacturing, and aerospace plastics.
- Lower maintenance: Because fiber lasers are solid-state with fewer moving parts increase the operational life and reduce the maintenance.
- High-speed marking: Their speed enables rapid or fast processing, even on high-volume production lines that involve plastic and metal components.
Limitations of Fiber Lasers
- Limited on Clear Plastics: Fiber lasers do not work well on clear materials such as clear acrylic, polycarbonate, or PETG, which are often used in many custom plastic fabrication jobs.
- Higher Initial Cost: Fiber lasers will have lower operational costs, but will incur a higher initial cost.
Main Differences between Carbon and Fiber Laser Etching?
| Feature | CO2 Laser | Fiber Laser |
| Best For | Organic materials, acrylics, and certain plastics | Metals, dark plastics, and polymers |
| Wavelength | 10.6 μm | 1.06 μm |
| Marking Speed | Moderate | Very Fast |
| Material Compatibility | Excellent for acrylic, ABS, PVC | Excellent for metals, dark plastics |
| Precision | High | Very High |
| Cost | Lower upfront, higher maintenance | Higher upfront, lower maintenance |
| Maintenance | Gas tube replacement is needed | Minimal |
Applications in Plastic Manufacturing and Fabrication
CO2 Laser Applications
- Signage & Displays: Often engraved on clear and colored acrylic displays will require detail of a higher level for the CO2 laser to produce fine detail, allowing you to engrave plastic without melting.
- Custom Fabrication: Used by plastic fabricators for cutting and marking plastic enclosures, containers, and cases.
- Packaging: Requires marking batch numbers and expiration dates on plastic film or cartons.
Fiber Laser Applications
- Medical Devices: Permanent part marking of codes on polycarbonate or PEEK components to ensure traceability and conformity.
- Automotive injection molding: Requires marking serial numbers and part id's for plastic and metal parts, often in an assembly process.
- Electronic Housings: Durable, high-contrast marking on dark engineering plastics such as ABS or polyamide.
Which Should You Choose?
Your perfect laser system depends on the material, scale, and goal of your project. Here is a very simple chart to help you determine:
Choose CO2 Laser If:
- You are working mainly with acrylic, ABS, PVC, or HDPE
- Have fine detail etching for signage, panels, or displays
- Have a custom fabrication shop, and are providing aesthetically pleasing finishes
- Need a greater area to be able to cut a plastic sheet
Choose Fiber Laser If:
- You need to mark metal components or dark-colored plastics
- You are in injection molding for high-tech or medical applications
- Are you looking for high-speed, high-contrast, and permanent marking solutions
- Need a low-maintenance, durable 24/7 solution
Cost Comparisons
| Expense | CO2 Laser | Fiber Laser |
| Initial Cost | $5,000 – $20,000 | $15,000 – $80,000 |
| Operational Cost | Moderate (gas refills, parts) | Low |
| Maintenance | Higher | Minimal |
| ROI | Great for plastic fabrication shops | Great for high-volume manufacturers |
If your business is based in plastic fabrication, you will get the best overall value using a CO2 laser. Whereas fiber lasers will provide a rapid return on investment for companies engaged in injection molding and who have mixed materials or metal marking needs.
Future Trends in Laser Marking
- Hybrid Laser Systems: This will provide both CO2 and fiber lasers in a single machine for greater applications by plastic manufacturers.
- AI-Powered Automation: Customers should expect greater speed in job setups, at times determining the material in real-time, improving accuracy, speed, and efficiency in custom fabrication.
- Environmental Emphasis: Laser marking is growing in popularity due to being a low-waste, chemical-free marking method.
Summary
Choosing between carbon and fiber laser etching depends on your specific use case. If your business is around custom plastic fabrication, acrylic signage, or injection molded plastic parts, the greener option is a CO2 laser. If you are trying to get high contrast, permanent marks on metal or industrial-grade polymers, the fiber lasers are worth considering.
As more industries start to turn to custom fabricators of plastic for detailed work, from automotive to medical, laser etching will only continue to grow in its importance in product branding, compliance, and traceability.
Be prudent about your investments. Etch with confidence.