Metal Engraving with a CO2 Laser: A Complete Guide

Metal engraving with a CO2 laser is a powerful method to create intricate designs, marks, or text on metal surfaces. Unlike fiber lasers, which are more traditionally associated with metal engraving, CO2 lasers can also handle this task with the right preparation and techniques.

In this article, we’ll explore how CO2 laser engraving on metal works, the best practices for success, and the materials and tools you’ll need.

How CO2 Laser Engraving on Metal Works

CO2 lasers primarily emit infrared light and are more suited for cutting or engraving organic materials like wood, leather, and acrylic. However, by using specific marking sprays or pastes, CO2 lasers can also engrave metals like stainless steel, brass, aluminum, and titanium.

Here’s how it works:

• Laser and Marking Agent Combination: When engraving metal, a marking agent (such as a ceramic-based spray or paste) is applied to the surface. This agent reacts with the laser, bonding to the metal and leaving a permanent, high-contrast mark.
• Heat Reaction: The heat from the CO2 laser causes the marking agent to fuse with the metal surface, resulting in a durable mark.
• Post-Engraving Cleaning: After engraving, the excess marking agent is washed off, leaving behind the engraved design.

Steps for CO2 Laser Metal Engraving

1. Choose the Right Metal and Marking Agent: For most metals, you’ll need to apply a marking agent. Choose an agent suitable for the metal type you’re working with, whether it’s stainless steel, aluminum, or other metal alloys. We recommend two options available on Amazon, here are the links: 12 Oz – BLI101 – Aerosol Black Laser Ink for Metals Marking – Brilliance Laser Inks and CerMark Ultra Laser Marking Aerosol. Find reviews of these marking agents below.
2. Clean the Metal Surface: Ensure the metal surface is clean and free of any oils or debris. A clean surface allows the marking agent to bond properly to the metal during the engraving process.
3. Apply the Marking Agent: Apply an even coat of the marking agent (such as CerMark, or Brilliance Laser Inks) to the metal. Follow the product’s instructions for drying time before engraving.
4. Set Up Your CO2 Laser Engraver: Load your design file into the laser software. Set the appropriate power, speed, and resolution settings according to the metal type and thickness. Metal engraving typically requires high power and slower speeds to ensure the laser properly reacts with the marking agent.
5. Engrave the Metal: Run the engraving process. The laser will bond the marking agent to the metal’s surface, creating a permanent, visible mark.
6. Remove Excess Marking Agent: Once the engraving is complete, wash off any excess marking agent using water and a soft cloth. The final result will be a crisp, clear engraving on the metal surface.

Best Practices for CO2 Laser Engraving on Metal

1. Use Appropriate Power Settings: Metal engraving generally requires high-power laser settings. CO2 lasers typically work best with 40W or higher power outputs for metal engraving.
2. Ensure Even Marking Agent Application: Apply a uniform coat of the marking agent to prevent streaking or uneven marks during engraving.
3. Test on Scrap Metal First: Always run a test engraving on a spare piece of metal to fine-tune your settings and ensure a perfect result on your final project.
4. Consider Using Multiple Passes: If your mark isn’t deep enough, try increasing the number of passes rather than boosting the laser’s power to avoid overheating the material.

Advantages of CO2 Laser Metal Engraving

• Versatile: CO2 lasers are versatile and can engrave a wide range of materials beyond metal, making them valuable for mixed-material projects.
• Non-Contact Process: Since laser engraving is a non-contact process, there’s no risk of damaging or distorting the metal surface.
• High Precision: CO2 lasers provide excellent precision, allowing for detailed designs and fine text engraving.

Limitations of CO2 Laser Metal Engraving

• Requires Marking Agents: Unlike fiber lasers, CO2 lasers need marking agents to engrave metal, adding an extra step to the process.
• Limited Metal Types: CO2 lasers can’t engrave all metals effectively. Thicker metals or certain alloys may require a fiber laser for deeper engraving.

The Best Marking Agents For Metal Engraving With A CO2 Laser

1. Brilliance Laser Inks 12 Oz Laser Marking Spray – Black (BLI101)

Brilliance Laser Inks 12 Oz Laser Marking Spray (BLI101) is widely regarded as one of the top-performing marking agents for metal engraving, especially when used with CO2 laser engravers. This aerosol-based solution offers permanent, high-contrast black marks on various metal surfaces, making it ideal for professional engravers and hobbyists alike.

Product Overview:

• Size: 12 oz aerosol spray
• Color: Black
• Compatible Laser Types: CO2, Fiber, YAG, and Diode
• Surface Compatibility: Suitable for a wide range of metals, including stainless steel, aluminum, brass, and more.

Features:

• High Contrast: Provides bold, black marks that stand out against metal surfaces.
• Permanent Bond: Ensures long-lasting durability on engraved items.
• Versatile Use: Works with multiple laser types, although it shines with CO2 lasers for metal engraving.
• Easy Application: Spray-on application allows for even coverage before laser engraving.
• Quick Drying: Dries in minutes, allowing for fast production without downtime.

Performance with CO2 Lasers:

When used with CO2 laser engravers, Brilliance Laser Inks’ BLI101 excels at providing crisp, clear markings on metals that would otherwise be difficult to engrave directly. The spray bonds with the metal surface during the engraving process, ensuring that the design is both permanent and resistant to wear over time.

Pros:

• Exceptional Contrast: The black markings are vivid and highly visible, enhancing the legibility of text or the clarity of intricate designs.
• Durability: The bond created is permanent, with the markings resistant to fading, scratching, or other wear.
• Versatile: Can be used with multiple laser types (CO2, Fiber, YAG, Diode), providing versatility if you work with different machines.
• Easy to Use: Simple spray application and fast drying time make the process user-friendly and efficient.
• Cost-Effective: A little goes a long way, making the 12 oz can ideal for multiple projects, especially for hobbyists and small businesses.

Cons:

• Surface Prep Required: Metals must be cleaned thoroughly before application for the spray to bond properly.
• Limited Color Options: Only available in black, which may not be ideal for all projects that require different marking colors.
• Slight Learning Curve: Finding the right thickness of the application can take some trial and error to get optimal engraving results.

Brilliance Laser Inks 12 Oz Laser Marking Spray (BLI101) is a standout choice for those who need a reliable marking agent for metal engraving with a CO2 laser. Its ability to create high-contrast, durable black marks on metal surfaces makes it a go-to for professional engravers and enthusiasts looking to elevate their projects.

While it requires proper surface preparation and attention to application, the results are consistently impressive, making it the best marking agent for metal engraving with a CO2 laser.

Final Verdict:

• Rating: ★★★★★
• Best For: Metal engraving with CO2 lasers, especially for creating high-contrast, permanent marks.

2. CerMark Ultra Laser Marking Aerosol, 2oz

The CerMark Ultra Laser Marking Aerosol (2oz) is widely regarded as one of the best marking agents for creating high-quality, durable engravings on metal surfaces. Designed specifically for use with CO2 laser engravers, it offers professional-grade results that are ideal for a wide range of industries, from industrial manufacturing to hobbyist crafting.

This spray creates deep, black markings that bond permanently to the surface, making it an essential tool for anyone working with metal laser engraving.

Product Overview:

• Size: 2oz aerosol can
• Color: Black
• Compatibility: Works on various metals including stainless steel, aluminum, brass, and chrome.
• Laser Compatibility: Ideal for CO2 laser engravers, but also compatible with Fiber, YAG, and diode lasers.

Key Features:

• High Contrast Markings: Produces deep, black, high-contrast markings that are easy to read and visually striking.
• Durable Bonding: The markings created are resistant to wear, chemicals, and high temperatures, ensuring long-lasting results.
• Easy Application: The aerosol spray allows for quick and even application on metal surfaces with minimal effort.
• Precision Results: Suitable for engraving detailed designs, logos, and text on metal surfaces, with sharp and accurate results.
• Versatile Use: Works on a wide range of metal substrates, making it ideal for everything from industrial to decorative applications.

Performance:

CerMark Ultra is known for its reliable performance when paired with a CO2 laser engraver. The spray applies smoothly and consistently, and once the laser engraving is complete, the markings are durable and highly legible. The spray adheres well to most metal surfaces, creating a permanent bond that holds up to heavy use, heat, and abrasion.

Pros:

• High-Quality Markings: Produces clear, bold, and long-lasting engravings with excellent contrast.
• User-Friendly: Easy-to-use aerosol spray simplifies the application process, requiring minimal setup and clean-up.
• Strong Durability: The engravings resist fading, wear, and environmental factors, ensuring they remain intact over time.
• Wide Compatibility: Works well on many types of metals and is compatible with multiple laser types.
• Great for Detailed Work: Perfect for fine details, small text, or complex designs due to its precision.

Cons:

• Small Size: The 2oz can is suitable for smaller projects but may not last long for larger-scale jobs, potentially requiring frequent reordering.
• Price: It’s more expensive than other marking agents, especially given the small size of the aerosol can.
• Surface Preparation: Metals need to be thoroughly cleaned and prepared for optimal results, adding extra steps to the process.

The CerMark Ultra Laser Marking Aerosol, 2oz, is an outstanding choice for achieving professional-quality metal engravings with a CO2 laser engraver. It’s easy to use, highly effective, and produces long-lasting, high-contrast results.

While the small size and higher price point may be a downside for some, the exceptional durability and clarity of the engravings make it well worth the investment for high-end projects.

Final Verdict:

• Rating: ★★★★☆
• Best For: Professionals and hobbyists seeking durable, high-contrast engravings on metal with a CO2 laser engraver.

Also Read: 

Can you laser engrave copper?

Can a Laser Engraver Engrave Silver?

How To Engrave Stainless Steel with A CO2 Laser Using Brilliance Laser Inks

Engraving stainless steel with a CO2 laser engraver is a powerful method for creating detailed and durable markings, logos, or designs on metal surfaces.

However, CO2 lasers are not directly compatible with metal surfaces like stainless steel without using a marking agent. We will explore the process of using Brilliance Laser Inks as the marking agent to achieve high-quality engravings on stainless steel.

Materials You Will Need:

• CO2 Laser Engraver
• Brilliance Laser Inks (12 Oz Black Aerosol)
• Stainless Steel Surface
• Cleaning Supplies (Isopropyl alcohol, lint-free cloth)
• Safety Gear (Goggles, gloves)

Step-by-Step Guide to Engraving Stainless Steel with a CO2 Laser

Step 1: Prepare Your Stainless Steel Surface

Before applying the marking agent, it’s important to thoroughly clean the stainless steel surface. This ensures that the engraving process goes smoothly and that the markings adhere properly. Use isopropyl alcohol and a lint-free cloth to wipe away any dirt, grease, or residue from the metal surface. Allow the stainless steel to dry completely before moving to the next step.

Step 2: Apply Brilliance Laser Inks Marking Agent

Shake the Brilliance Laser Inks aerosol can for about 1-2 minutes to ensure the ink is well-mixed. Holding the can approximately 6-8 inches away from the stainless steel surface, apply an even coat of the ink.

Make sure the surface is fully covered with a thin layer. Avoid over-spraying or creating thick, uneven coats, as this can affect the quality of the engraving.

Let the marking agent dry completely. This may take a few minutes, depending on your workspace conditions.

Step 3: Set Up Your CO2 Laser Engraver

After applying the marking agent, set up your CO2 laser engraver. Since stainless steel is a reflective metal, CO2 lasers cannot engrave it directly. However, the marking agent allows the laser to create a bond with the metal surface, producing a dark, high-contrast engraving.

To achieve the best results:

• Laser Power: Start with a lower power setting and gradually increase if needed (30-50% power is generally recommended).
• Speed: Adjust the engraving speed depending on the detail of the design. A slower speed allows for deeper marking.
• Resolution: A resolution setting of 300 to 500 DPI typically yields clear and precise engravings.

Step 4: Begin the Engraving Process

Once your settings are adjusted, begin the engraving process. The laser will interact with the Brilliance Laser Ink to mark the stainless steel surface. During engraving, ensure that you have proper ventilation, as fumes may be released from the marking agent.

Step 5: Clean the Surface

After the engraving is complete, allow the stainless steel to cool down for a few minutes. Then, use a clean cloth and water to wipe away any excess marking agent left on the surface. The result will be a high-contrast, permanent engraving that stands out sharply against the stainless steel.

Tips for Achieving the Best Results:

• Use a Test Piece: Always test your laser settings on a scrap piece of stainless steel before engraving the final piece.
• Ensure Even Application: Apply Brilliance Laser Inks evenly to avoid patchy or inconsistent engravings.
• Optimize Your Laser Settings: Adjust the power, speed, and resolution based on the complexity and size of your design.

Why Use Brilliance Laser Inks for Stainless Steel Engraving?

Brilliance Laser Inks is an excellent choice for CO2 laser engraving on stainless steel due to its high durability and ability to create strong, long-lasting bonds with metal. Here’s why it stands out:

• High-Contrast Markings: The black aerosol spray creates deep, bold engravings that are easy to read and visually striking.
• Durability: Markings created with Brilliance Laser Inks are resistant to fading, wear, and exposure to heat or chemicals.
• Easy Application: Its aerosol form allows for quick, uniform coverage on stainless steel surfaces.

Engraving stainless steel with a CO2 laser engraver may seem challenging, but with the right tools and techniques, it becomes a straightforward process. By using Brilliance Laser Inks as a marking agent, you can achieve professional-grade, high-contrast engravings on stainless steel that will stand the test of time.

Always ensure to prepare your surface correctly, fine-tune your laser settings, and follow safety procedures for the best possible results.

Related Post: Best methods for laser engraving stainless steel

What Metal Materials can be engraved directly with a CO2 Laser without any marking agents?

CO2 laser engravers are popular for engraving a wide range of materials like wood, acrylic, leather, and certain plastics. However, when it comes to metals, CO2 lasers often require marking agents or special coatings to create high-quality engravings.

Despite this, certain metal materials can be engraved directly by CO2 lasers without the need for any marking agents. We’ll explore which metals can be engraved directly with a CO2 laser engraver and how to achieve the best results.

Understanding CO2 Laser Technology

CO2 laser engravers work by emitting a high-powered infrared laser that interacts with the surface of the material being engraved. This laser vaporizes or ablates the material to create detailed markings. The challenge with metals is that they reflect the CO2 laser’s infrared light, making direct engraving difficult.

However, certain metals can still be engraved directly due to their unique surface properties or pre-treatment processes.

Metals That Can Be Engraved Directly with CO2 Lasers

1. Anodized Aluminum
   • Overview: Anodized aluminum is one of the most common metals that can be engraved directly by a CO2 laser. The anodizing process creates a porous oxide layer on the aluminum surface that absorbs the CO2 laser energy.
   • Engraving Quality: The laser removes the anodized layer, revealing the raw aluminum beneath. This produces a high-contrast, detailed engraving. You can achieve clean, white or silver markings that stand out against the anodized color.
   • Uses: Ideal for marking identification plates, promotional products, and custom designs on anodized aluminum surfaces.
2. Painted or Powder-Coated Metals
   • Overview: CO2 lasers can directly engrave metals that have been painted or powder-coated. The laser vaporizes the paint or coating layer, exposing the bare metal underneath.
   • Engraving Quality: Engravings appear as the base metal contrasts with the colored coating, resulting in sharp, visible marks.
   • Uses: Commonly used for metal signs, plaques, and custom metal products with a painted surface.
3. Treated Stainless Steel (Pre-Coated or Lacquered)
   • Overview: Stainless steel generally requires a marking agent for CO2 lasers, but pre-treated or lacquered stainless steel can sometimes be engraved without one. If the surface has a dark-colored coating or lacquer, the CO2 laser can etch away the coating to reveal the stainless steel underneath.
   • Engraving Quality: You will get a contrasting look, depending on the color of the coating and the base metal. The result is often less durable than fiber laser engravings on raw stainless steel but still visually appealing.
   • Uses: Suitable for decorative items, signs, or plaques with a treated surface.
4. Alumamark Aluminum
   • Overview: Alumamark is a specialized aluminum product that is designed specifically for CO2 laser engraving. The material is coated to absorb the laser’s energy and create crisp, dark engravings.
   • Engraving Quality: The result is sharp, permanent black markings without the need for marking agents.
   • Uses: Ideal for awards, signs, nameplates, and industrial applications where permanent labeling is required.
5. Powder-Coated Stainless Steel
   • Overview: Powder-coated stainless steel can be directly engraved with a CO2 laser by burning away the coating and revealing the steel surface. The engraving creates a clear contrast between the polished steel and the dark coating.
   • Engraving Quality: This method results in well-defined marks but is dependent on the quality of the powder coating and the laser settings.
   • Uses: Perfect for engraved logos, designs, or text on stainless steel products that have a powder-coated finish.
6. Brass-Plated or Coated Metals
   • Overview: Certain brass-plated metals or those with a lacquered coating can be engraved with a CO2 laser by removing the coating to reveal the shiny brass layer underneath.
   • Engraving Quality: The laser creates a sharp contrast between the polished brass and the dark or matte coating.
   • Uses: Often used for decorative items, signage, or plaques where a brass look is desired.

How to Achieve the Best Results for Direct Metal Engraving

1. Optimize Laser Settings: Metals are more challenging to engrave with a CO2 laser, so it’s important to fine-tune your laser settings. Adjust the power, speed, and frequency of your laser to achieve the desired depth and clarity of your engraving.
   • Higher Power: Metals often require higher power settings compared to other materials.
   • Slower Speed: Reduce the engraving speed to give the laser more time to interact with the metal surface.
2. Use Multiple Passes: For some metals, you may need to perform multiple engraving passes to achieve the desired depth and detail. This is especially true when engraving painted or lacquered surfaces.
3. Ensure Proper Ventilation: Engraving metals can produce fumes, especially when removing paint or coatings. Ensure your workspace is well-ventilated, and use an exhaust system to remove fumes.
4. Test on a Sample: Always perform a test on a scrap piece of metal to verify your settings before engraving the final product. This helps you avoid errors and ensures the highest quality result.

While CO2 lasers are not typically used for direct engraving on bare metals, certain treated and coated metals like anodized aluminum, powder-coated stainless steel, and painted surfaces can be engraved directly without the need for marking agents. By optimizing your laser settings and understanding the properties of the metal you’re working with, you can achieve professional-quality engravings with a CO2 laser.

Whether you’re engraving industrial parts, custom signs, or promotional products, these metals allow you to make the most of your CO2 laser engraver without the extra step of applying marking agents.

Final Thoughts

Metal engraving with a CO2 laser offers an efficient and effective way to mark metals when using the proper tools and techniques. While fiber lasers are generally more suited for metal engraving, CO2 lasers, when paired with a marking agent, provide an excellent alternative for adding personalized designs or durable markings to metal surfaces.

By following the steps outlined in this guide and paying close attention to laser settings, you can achieve professional-quality engravings on a variety of metals.