Although extruded acrylic has limited color selection (clear, opal and black) cutting extruded is much cleaner than cast. The laser vaporizes through extruded more easily leaving a smooth, almost glass-like, flame polished edge. Its also cheaper than cast. Cast is harder to flame polish and you’ll notice a slightly rougher edge. But, cast has that nice white contrast when engraved.
Keep in mind that laser cutting acrylic can produce flare ups so be sure to stay near the laser during processing. If you get a flare up during cutting (especially thick acrylic where more power is necessary) you can mask both sides of the acrylic cut area with transfer tape (paper mask) that has been slightly dampened. Alternatively applying liquid dish soap instead of tape can help prevent smoke and residue damage. When you’re done you simply rinse and repeat!
NOTE: Do not use vinyl masks since the laser will trigger a thermal process that will emit hydrochloric acid and toxic fumes.
Some of the more popular laserable acrylic applications include:
illuminated (LED) or clear signs
laser cut acrylic letters
architectural model making with acrylic
acrylic advertising (point of sale) displays
photo etching or engraving on acrylic
outdoor or indoor signage
acrylic awards and trophies
acrylic home decor pieces