HDPE vs Acrylic for Laser Cutting: Which One Should You Buy?

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HDPE vs acrylic for laser cutting: the short answer

For laser work, the acrylic sheet in this guide is the stated choice. The Trotec TroLase listing describes a two-ply modified acrylic sheet for laser engraving, with a thin top layer over a modified acrylic core, so engraving reveals the contrasting core. It states laser engraving and cutting with a CO2 laser, and laser engraving with a diode laser, plus rotary engraving, hot stamping, and cutting with saws or guillotines. The HDPE sheets state a different kind of work: CNC, machining, industrial use and DIY fabrication. The Sasylvia listing names cutting, trimming, routing, drilling and shaping as ways to work its sheet. That difference in stated use, not the sheet thickness, is what decides this comparison.

What each listing states about use

The Sasylvia HDPE sheet listing names CNC, machining, marine boards, outdoor panels, industrial equipment liners and DIY fabrication. It describes a sheet that resists wear and tear, is not easy to crack, can replace wood or metal in other materials, and can withstand heavy loads and harsh conditions. The Threehoney HDPE sheet listing names machinery, the mining industry, the textile industry, home industry, crafts, fabrication and machining. It describes a sheet that resists corrosion and most acid, alkali and salt medium, with high surface tension and a small friction coefficient, so it does not easily stick or leave dirt. The Trotec acrylic listing names laser engraving, outdoor signs and decoration, labels, badges and handicrafts, with digital, UV and screen printing named as further uses for the double color sheets.

Thickness, size and sheet form

The Sasylvia sheet measures 1/2 inch thick, 36 inch wide and 72 inches long in its title and bullets. Its spec table gives a different size, 24 inch x 48 inch, against the title and bullets; this guide follows the title and bullets at 36 inch by 72 inches. The Threehoney sheet measures 1/4 inch thick, 24 inch wide and 48 inches long, and weighs 12 pounds. The Trotec acrylic sheets measure 12 inch by 12 inch, with a thickness of 1/16 inch, given as 0.06 inch and 1.6 mm, and an engraving depth the listing gives in two different figures, 0.003 inch and 0.8 mm. The Trotec set holds 8 pieces in multicolor, with Black/White, Red/White, White/Black, Blue/White, Black/Red, Yellow/Black, Green/White and Orange White in the sheet list. Both HDPE sheets are white, single sheets in rectangular form, and both listings note that the sheet is not coated with film, so slight scratches during transportation may occur but do not affect use.

Gear: three sheets, three stated jobs

Trotec TroLase modified acrylic, the laser sheet. Two-ply modified acrylic, 12 inch by 12 inch, 1/16 inch thick, in a set of 8 pieces. The listing states CO2 laser engraving and cutting, diode laser engraving, rotary engraving and hot stamping, with UV light resistance for outdoor signs. Engraving depth is stated at 0.003 inch.

Sasylvia white HDPE, the large CNC sheet. HDPE plastic, 1/2 inch thick, 36 inch by 72 inches. The listing states CNC, machining, marine boards, outdoor panels and industrial equipment liners, and says the sheet can be cut, trimmed, routed, drilled or shaped to specification.

Threehoney white HDPE, the smaller DIY sheet. HDPE plastic, 1/4 inch thick, 24 inch by 48 inches, at 12 pounds. The listing states DIY projects, crafts, fabrication, machining and home use, with corrosion resistance and resistance to most acid, alkali and salt medium.

Cutting safety: fire, smoke and fumes

Laser cutting makes smoke that needs to leave the room, so plan ventilation before the first cut: exhaust outdoors or use a filter designed for laser fumes. Keep a suitable extinguisher within reach and never leave a running job unattended. Eyewear protects only when its listing states an optical density and a wavelength range that matches the laser. Never laser PVC, vinyl, PVC-based faux leather, polycarbonate or ABS. They can release harmful fumes, and chlorinated plastics can damage the machine, so keep them out of the laser bed entirely, even when a sheet looks like a safe plastic.

Which sheet for which job

• Laser engraved signs, labels and badges: the Trotec acrylic sheets, with UV light resistance stated for outdoor signs and decoration.
• Large panels, marine boards and industrial liners: the Sasylvia HDPE sheet, at 1/2 inch thick and 36 inch by 72 inches, for CNC and machining work.
• Smaller DIY, crafts and home fabrication: the Threehoney HDPE sheet, at 1/4 inch thick and 24 inch by 48 inches, for home and craft projects.

FAQ: lasers and CNC

Can you laser cut HDPE?

The HDPE listings in this guide do not state laser cutting. They state CNC, machining, industrial and DIY uses. The acrylic listing states laser engraving and cutting, so it is the laser sheet in this guide.

Can a diode laser cut the acrylic sheet here?

The Trotec listing states CO2 laser engraving and cutting and diode laser engraving. It does not state diode laser cutting in the same wording, so confirm the diode cutting claim on the listing before cutting with a diode laser.

What thickness are the sheets in this guide?

The Sasylvia HDPE sheet is 1/2 inch thick, the Threehoney HDPE sheet is 1/4 inch thick, and the Trotec acrylic sheets are 1/16 inch thick, given as 0.06 inch.

Are the HDPE sheets coated with film?

No. Both HDPE listings note that the sheet is not coated with film, so slight scratches during transportation may occur, but the listings state that this does not affect use.

Can the acrylic sheet be used outdoors?

The Trotec listing states UV light resistance and UV stability for outdoor signs and decoration, with an ISO 4892 figure of two years without any color change or fading.

Related: acrylic sheets for laser cutting, acrylic vs HDPE for CNC, how to laser cut acrylic without melting edges and engraving materials.