Corrugated Plastic Laser Cut Settings

If you've been searching for the exact settings to laser cut corrugated plastic - you're in the right place.

Co2 lasers,DIY,laser business,laser cutter,xtool P2,

I made a full set of photo booth props and big head cutouts for my daughter's graduation party using corrugated plastic. I've also used this same material to make holiday yard sign decorations so knowing how to cut coroplast is super helpful!

I'm going to give you the exact numbers so you don't have to spend time doing test cuts like I did.

What kind of corrugated plastic should you use?

Not all corrugated plastic is the same. You want to make sure you're using a laser-safe version that won't release toxic fumes when cut. I use these corrugated plastic sheets from Amazon. They're slightly too big for my largest laser, but I just trim them down or in half using a utility knife.

These sheets are the same material yard signs are made from. They're lightweight, rigid, and weather resistant which makes them perfect for photo booth props, big heads, yard signs, and holiday decorations.

Laser cut settings for corrugated plastic on the xTool P2

Here are the exact settings I use in xTool Creative Space when laser cutting with my xTool P2, a 55w CO2 laser:

Mode: Cut
Power: 77
Speed: 21
Passes: 2

A few important tips before you cut:

Save your settings as a custom material. Once you find settings that work, save them as a custom material preset in xTool Creative Space so you never have to hunt for them again. Click the save icon next to your settings and name it something like "Corrugated Plastic."

Use an SVG cut file, not a colored image. xTool Creative Space doesn't like fully colored files. Create a separate SVG with just the cut outline - red fill, transparent background - for the laser. Save your full color version as a PNG for UV printing.

Don't leave your laser unattended. Corrugated plastic can create a small flame while cutting. Stay close and keep an eye on it and make sure your air filter is clean. I actually switched to my xTool AP2 filter for this job and greatly reduced the amount of smoke.

For the full laser cutting walkthrough including a demo of the cut settings in action:

How to pop out your designs cleanly

Once cutting is done, you might find some pieces don't pop right out - especially intricate shapes. Don't force it or you'll bend the plastic.

Instead, take a utility knife and gently score along one straight edge of the cut line to get it started.

Once you break the first edge, the rest of the piece will pop out cleanly. You don't need to go around the entire design - just start it.

Pro tip: If you're planning to UV print on the piece, don't pop it out after laser cutting. Leave it sitting in the plastic sheet and place the whole thing on your UV printer bed. The surrounding plastic acts as a built-in jig and protects your printer bed from overspray.

For the full UV printing walkthrough with a step-by-step demo:

What can you make with laser cut and UV printed corrugated plastic?

So much! Here's what I've made so far:

Photo booth props (school logos, fun shapes)
Big head cutouts for graduation parties, sports events, and birthdays
Yard signs
Holiday decorations

If you want to see how I used these for my daughter's graduation party - including how I made the big head cutouts start to finish - check out this video:

Shop the supplies

Need one-on-one help getting your settings dialed in? That's exactly what Silhouette U is for. I offer same-day support for lasers, UV printers, Silhouette machines, and more.

Visit www.silhouetteu.com and use code YOUTUBE for 50% off.

Note: This post may contain affiliate links. By clicking on them and purchasing products through my links, I receive a small commission. That's what helps fund Silhouette School so I can keep buying new Silhouette-related products to show you how to get the most out of your machine!

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