How to Use Honeycomb Pins to Keep Material Flat When Laser Cutting

When laser cutting, achieving a perfect cut depends on precise alignment and laser focus. One often overlooked but critical aspect of this process is ensuring your material lays completely flat on the laser bed. A small warp or lift in the material can lead to uneven cuts, misaligned engravings, or even failed projects.

Honeycomb pins are a simple yet effective solution to keep your material flat and stable during laser cutting. Here’s how to use them and why they’re indispensable for achieving professional results.

Why Keeping Materials Flat is Essential

1. Improved Laser Focus:
   The laser is calibrated to focus at a specific height. If the material isn’t flat, parts of your design may be out of focus, leading to incomplete cuts or inconsistent engravings.

2. Consistent Results:
   Warping can cause misalignment or uneven pressure on lightweight materials, affecting cut accuracy.

3. Prevention of Errors:
   Flawed cuts due to uneven surfaces often waste materials, time, and effort. Using honeycomb pins reduces the likelihood of such errors.

What Are Honeycomb Pins?

Honeycomb pins are small clips or wedges designed to fit snugly into the honeycomb grid of your laser cutter bed. They apply gentle pressure to your material, holding it flat and in place during the cutting or engraving process. They’re typically made from materials like acrylic, plywood, or even metal, depending on the design.

When to Use Honeycomb Pins

• Warped Materials: Boards with slight bows or warps.
• Lightweight Materials: Cardboard, mat board, chipboard, and other materials prone to movement from air assist.
• Delicate Projects: Thin or intricate cuts where even slight material movement can ruin the design.

How to Use Honeycomb Pins

1. Prepare Your Material:

   • Place your material on the honeycomb laser bed.
   • Check for any visible gaps between the material and the honeycomb grid.

2. Insert Honeycomb Pins:

   • Slide the pins into the honeycomb grid at strategic points around the material.
   • Push the material down gently and use the pins to apply light pressure.
   • Ensure the pins don’t interfere with the laser path or design.

3. Test for Flatness:

   • Run your hand lightly over the material to confirm it’s flat and secure.
   • If there are any lifted edges, reposition or add more pins as needed.

4. Start Cutting or Engraving:

   • Once everything is flat and secure, proceed with your laser job.

Benefits of Using Honeycomb Pins

• Improved Stability: Keeps materials firmly in place, even with air assist or during rapid movements.
• Better Cutting Accuracy: Ensures the laser maintains a consistent focus height across the entire project.
• Versatility: Works on a variety of materials, from rigid boards to lightweight papers.
• Reusability: Most honeycomb pins are durable and can be used repeatedly.

DIY Honeycomb Pins

If you don’t already have honeycomb pins, you can easily make them using a laser cutter. Many free designs are available online. Here’s how to get started:

1. Choose a Design: Look for honeycomb pin designs that suit your bed size and project needs.
2. Select Material: Acrylic or plywood (around 3mm thick) works well for durable pins.
3. Cut and Assemble: Follow the design instructions to create your pins.

Other Methods for Keeping Material Flat

While honeycomb pins are an excellent solution, here are some additional techniques to keep your material flat:

• Masking Tape: Tape down the edges of lightweight materials to prevent movement.
• Magnets: If your laser bed is metal, use small magnets to hold the material in place.
• Weights: Place small, heavy objects (like washers) on non-cutting areas of the material.

Final Thoughts

Using honeycomb pins is an easy and effective way to ensure your material remains flat during laser cutting. This simple step can save you frustration, improve accuracy, and reduce wasted materials. Whether you're working with warped wood or lightweight cardboard, honeycomb pins are a reliable tool to keep your projects on track.

Click here to get a free file for honeycomb pins from our website. This file works on Glowforge Performance Lasers and most Aeon Lasers.