Don't Let Your Laser Cutter Hold You Back Cutting BIG Acrylic Sheets is Easier Than You Think!

Don't Let Your Laser Cutter Hold You Back Cutting BIG Acrylic Sheets is Easier Than You Think!

K
Kim and Garrett make it
1 Video View·Sep 12, 2025

Cutting a giant acrylic sign on a CO2 laser when your bed is too small. In this step by step build we use the pass through in LightBurn to cut a full 4x8 sheet of quarter inch acrylic into a 2x5 self standing, bottom lit sign. You will see our complete workflow including design layout, slicing the file for pass through cuts, adding registration marks, test cuts, squaring and spacing, and assembly with MDF letters and clear CA glue. We also show how we UV print a 24x24 panel, then align and glue everything cleanly for a pro finish.

👉 AEON Nova 14 Laser: https://aeonlaser.us/promos?ref=kandgmakeit

What you will learn
• How to plan a bigger than the bed project in LightBurn using Cut Shapes and Print and Cut
• Where to place registration marks so both halves line up
• How to run inexpensive cardboard test passes before touching your acrylic
• CO2 laser settings we used on our machine for quarter inch acrylic and eighth inch MDF
• Tips for squaring the stock, using a spacer to repeat the same left offset, and catching the sheet at the end of the cut
• Glue tests clear vs black CA on clear acrylic and why we chose clear
• Bottom lighting ideas for edge lit effects on thick acrylic

Chapters
00:00 Pass through plan cutting a 4x8 sheet of acrylic
01:45 LightBurn layout slice with Cut Shapes and registration marks
03:30 Cardboard pass through test and framing
05:10 Test card for quarter inch acrylic settings
07:00 First pass through cut and sheet handling
09:10 Continuation cut with Print and Cut alignment
11:00 Cutting the eighth inch MDF letters
12:20 UV printing the 24x24 panel
13:30 Glue test clear vs black CA and final assembly
15:30 Bottom lighting and final reveal

Helpful details
• Material acrylic clear quarter inch 4x8 sheet cut into 24x60 main panel plus feet
• Letters eighth inch MDF painted black
• LightBurn tools used Cut Shapes Print and Cut score lines registration marks
• Our test card landed on 10 power and 50 speed for quarter inch acrylic and quarter inch MDF on our setup. Your machine will vary so always test
• Assembly clear medium CA with activator light score lines used as placement guides plus tiny 0.01 offset to hide scores

Stuff We Used:
👉 AEON Nova 14 Laser: https://aeonlaser.us/promos?ref=kandgmakeit
https://www.amazon.com/shop/kimandgarrettmakeit

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FYI: We are not professionals, and we don’t claim to be. This is what we found worked for our project. Yours may need a little different approach. We have just enough woodworking skill to make some basic furniture. Safety first!


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