Sign manufacturing has always been about precision, creativity, and efficiency. As customers demand intricate, high-quality signage, sign shops need tools that deliver faster, cleaner, and more cost-effective results.
For decades, plasma, waterjet, and CNC routers have been the go-to methods for cutting metal and other sign materials. But these older technologies come with limitations—burn marks, slow cutting speeds, expensive consumables, and excessive post-processing.
Now, more and more sign manufacturers are turning to laser cutting, a technology that offers unmatched precision, speed, and cost savings. Publications like Signs of the Times and Sign Builder Illustrated report that sign shops are rapidly adopting laser technology to improve efficiency and expand their capabilities.
Let’s explore why laser cutting is transforming the sign industry—and why it might be the right move for your business.
1. Laser Cutting Produces the Cleanest, Sharpest Edges
One of the biggest challenges in sign making is achieving a smooth, precise cut without needing extra finishing work.
Many traditional cutting methods—like plasma and CNC routers—leave rough edges, burn marks, or require secondary grinding and polishing. These extra steps slow down production and add labor costs.
Laser Cutting Advantages:
- Perfectly smooth edges: Laser cutting achieves high precision, with tolerances as tight as ±0.1 mm, resulting in clean cuts that often require no further finishing.
- No Burn Marks: The non-contact nature of laser cutting minimizes thermal distortion, preventing burn marks even on delicate materials.
- Extreme Precision: Capable of intricate designs and fine details, laser cutting allows for complex patterns that are challenging for other methods.
By switching to laser cutting, sign shops can reduce post-processing time by up to 40%, allowing them to increase production efficiency and lower labor costs.
2. Faster Cutting Means Faster Production—And More Profits
In the fast-paced world of sign making, every minute counts. The longer it takes to cut a sign, the fewer jobs you can complete. And with tight deadlines, long turnaround times can mean lost business opportunities.
Many traditional cutting methods—like CNC routers and waterjet systems—require:
- Frequent tool changes to handle different materials.
- Slower cutting speeds, especially for detailed signage.
- Extra time for finishing work like sanding or deburring.
Laser Cutting Is Faster:
- Cuts at high speeds—laser beams move without mechanical resistance.
- Instant material switching—no need to swap bits or adjust settings.
- Clean cuts mean no extra finishing work—reducing total job time.
Real-World Example: When cutting 1.0mm stainless steel, laser cutters can reach speeds of 23.28 cm/second, which is significantly faster than other cutting methods.
But speed isn’t just about how fast the machine cuts—it’s also about workflow efficiency. With laser automation features like shuttle tables and digital programming, sign shops can process more jobs in a day without extra labor. That means less downtime, faster turnaround, and ultimately, more revenue.
3. Lower Operating Costs and Higher Return on Investment
Many sign shop owners and operators assume that laser cutting is expensive, but when you look at the numbers, the long-term savings are significant.
There are hidden recurring costs with other cutting methods:
- Plasma cutting → Requires expensive gas, electrode replacements, and frequent maintenance.
- Waterjet cutting → Abrasive materials alone can cost $30K+ per year for a busy shop.
- CNC routers → Bit replacements and manual labor drive up costs over time.
While the initial investment in laser cutting equipment can be substantial, the return on investment is compelling.
Laser Cutting is More Cost Effective:
- No consumables—no gas, abrasives, or cutting bits to replace.
- Minimal maintenance—no mechanical wear on cutting tools.
- Less material waste—laser nesting technology reduces scrap by up to 40%, maximizing efficiency.
Additionally, the U.S. laser cutting machines market is projected to grow, indicating a positive outlook for businesses investing in this technology.
Even better? Businesses investing in laser cutting machines can take advantage of Section 179 tax savings. In 2024, the tax deduction limit is $1,160,000, and businesses can write off the full purchase price of qualifying equipment.
💰 Example: If a sign shop purchases a $500,000 laser cutting system, they could save up to $175,000 in taxes, assuming a 35% tax rate.
Many sign shops find that a laser cutter pays for itself within a year, simply by eliminating outsourcing costs, consumable expenses, and excess labor time.
4. More Creative Possibilities & Material Versatility
One of the biggest advantages of laser cutting is its ability to work with a wide range of materials—but it’s important to choose the right type of laser for your needs.
CO₂ vs. Fiber Lasers: What’s the Difference?
- CO₂ Lasers – Best for non-metal materials like wood, acrylic, plastics, and composites. These lasers produce clean cuts and smooth edges in organic materials but aren’t effective for cutting metals.
- Fiber Lasers – Designed for metal cutting, including stainless steel, aluminum, brass, and copper. They can’t cut wood, acrylic, or plastics but offer high precision and speed on metals.
- Hybrid Systems – Some machines combine both CO₂ and fiber lasers, allowing shops to work with both metals and non-metals, though these systems tend to be more expensive.
Choosing the Right Machine for Your Business
If your sign shop primarily works with acrylic, wood, and plastics, a CO₂ laser is the best choice. If you cut metal signs, a fiber laser is the way to go. For shops that need to handle both, a dual-laser or hybrid system may be worth considering.
Materials and Their Compatible Laser Types:
| Material | CO₂ Laser | Fiber Laser |
|---|---|---|
| Acrylic & Plastics | ✅ Yes | ❌ No |
| Wood & MDF | ✅ Yes | ❌ No |
| Composites & Laminates | ✅ Yes (Some) | ❌ No |
| Metals (Steel, Aluminum, Brass) | ✅ Yes (Some) | ✅ Yes |
| Copper & Reflective Metals | ❌ No | ✅ Yes |
5. Laser Cutting Automation Provides Maximum Efficiency
Modern sign shops are looking for ways to streamline operations and reduce labor costs. Laser cutting systems integrate with automation tools to make sign production more efficient and scalable.
How laser cutting improves automation:
- Shuttle tables allow for non-stop production, increasing output.
- CAD/CAM software integration means seamless digital design-to-production workflows.
- Unattended operation lets machines run with minimal supervision.
With these features, sign manufacturers can increase production capacity without needing to hire additional labor, making it easier to scale their business profitably.
The Future of Sign Making is Laser Cutting
The shift toward laser technology in sign manufacturing is happening now. As the industry moves away from slow, high-maintenance, and expensive cutting methods, laser systems are becoming the go-to solution for shops that want to improve efficiency, cut costs, and deliver high-quality results.
The 5 Reasons Why More Sign Shops Are Choosing Laser Cutting:
- Cleaner, sharper cuts with no post-processing.
- Up to 3X faster than waterjet, plasma, or CNC.
- Lower operating costs with no consumables.
- Versatile material cutting for expanded sign-making capabilities.
- Automation-ready for higher production efficiency.