We recently tackled a great project: creating the pattern pieces for the GBR SailGP Team Buoyancy aids.
And guess what? Our trusty laser cutter was one of the key bits of kit. It allowed us to produce repeatable, detailed patterns for a small batch production run right here in the UK. This got us thinking – how crucial is laser cutting in modern product design? Read on as we can dive into Laser Cutting ‘Lens first’!
So, what exactly is laser cutting? Simply, it’s a technology that uses a focused laser light beam to cut or etch materials. Think of it as a super-precise lightsabre, it melts, cuts or vaporises material to create permanent marks or cuts. At Mouse we use a CO2 laser, but there are a several varieties from fibre to diode lasers, each with a different type of cutting our engraving output. The power and laser type dictate how thick a material it can cut, how deep it can etch and the materials it can work with. Our CO2 Laser is a great middle ground tool which can work with a lot of materials.
The process is quite straightforward. You start with a 2D CAD file; a line drawing – and import it into a laser programming software. Then, we set parameters like power, speed, and duration to determine whether we’re cutting, etching, or creating a rasterised picture effect. Before you ask, yes, I did set up the machine and then proceed to etch a photo of my kids on a bit of wood, because I could!
One of the coolest things about laser cutting is it is a non-contact process. So after we lay the material flat on the bed, the laser does its magic, but a series of mirrors and lenses focusing a fine beam onto the work. There is no need for clamps or tools that physically touch the material. Laser cutting can be done to a wide range of materials: plastics, woods, fabrics, paper, cardboard, and even some metals. And because it’s laser, the precision and repeatability are really good.
Laser cutters are just another tool in our product development toolbox – though honestly our toolbox is starting to feel more like Mary Poppins’ handbag! You never know what exciting gadget will pop out next!
Laser cutters are used for creating 2D components. Take the SailGP buoyancy aids, for example. Sail GP PFD’s We crafted 100’s of intricate fabric patterns that would’ve been a nightmare to cut by hand, saving time, increasing reliability and reducing waste. We also heavily used the laser cutter on the PPECO Face Visor PPECO to craft some 60 variations during development.
The 2D components that come off the laser cutter become the building blocks for 3D products, whether sewn, folded, glued, or screwed together.
One of the other advantages is it is really fast. Imagine cutting fabric patterns by hand finding out you needed to alter a tiny bit, you need to create a new paper pattern, draw round it on the fabric and then cut it out by hand. Versus making a quick change to a 2D drawing and reprocessing it on the laser cutter, its probably 5 time faster! This speed is crucial for rapid iteration, especially in fabric design work. Plus, when it’s time for larger production runs, we have the exact pattern profiles ready to go and can share these with the factory or use them for our own production runs.
Finally, let’s not forget customisation as laser cutting eliminates the need for expensive tooling, making it perfect for personalised products. The sort of thing you may buy for a present on Esty like engraved jewellery, keepsakes, or even custom laptop and phone cases. What stop the press is that how they make all that personalised stuff on Esty…
…well yep quite a bit of it!
Why do we love laser cutting? First, no tooling costs, traditional tooling like press tools, dies, and moulds can be pricey, especially for one-off projects or small runs. Laser cutting offers a cost-effective alternative.
Second, personalisation. We can create unique, personalised products quickly and accurately. The fine laser beam and adjustable spot diameter allow for incredibly detailed work.
Third, versatility. Laser cutting is adaptable to a wide range of design needs. It’s no wonder it’s become a mainstay on platforms like Etsy, where many businesses use it for production runs.
Our work on the PPECO Face Visor and SailGP buoyancy aids wouldn’t have been possible without our laser cutter. It’s a critical tool in our workflow.
In summary, laser cutting offers low cost, rapid iteration, precision, and customisation. If you’re looking to develop a laser-cut product or need production assistance, get in touch! We’re here to help bring your ideas to life
