Cutting gaskets from EVA foam with a diode-LASER

One of the great things about having a CNC machine is that we can make very professional looking projects whenever we want to. So sometimes we’ll want to add those nice details that make a project stand out. Things like, for example, gaskets between parts. Recently I had a need to cut a couple of 50 mm square gaskets for a 3D printed extractor project, for which I chose to use commonly available EVA foam sheet. So I thought I’d write a quick post to let you know how that went with my diode-LASER and whether EVA foam is useful for low-power LASER-cutting on a CNC router.

As you can see from the photo above, my 5W diode-LASER module cut right through the sheet easily with the power set to 25% and a feed rate of 200 mm/min. I’ve cut EVA in the past with a 1500 mW LASER module too, so those settings sound quite comparable and show that low-power LASER’s cut EVA well. At those settings I didn’t find any burning of the foam, and the shape came out pretty much as planned with just a little shrinkage at the edges. Plus, as the photo below shows of the MDF sheet I cut the EVA foam on, the LASER energy left after it had passed through the sheet was small: although probably I could have used a lower LASER-power just as well.

A photo of the laser cut EVA foam gasket together with a photo of the limited damage to the underlying MDF sheet

If you decide to LASER-cut some EVA too, please remember to use lots of ventilation as the fumes are unpleasant: given the small amounts of fumes you’re likely to create you may be tempted to skip the ventilation, but be warned that there have been reports of some EVA foam containing chlorine, which could make the fumes quite hazardous. So please make sure the foam you use is safe for LASER-cutting and use plenty of ventilation just in case 🙂

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