How to Cut Plywood for Die Cut With a Laser?

If you create stencils, packaging, craft dies, ornaments, or custom shapes, you’ve probably wondered how to cut plywood for die cut with a laser without burning edges, leaving char marks, or dealing with warped wood. Laser die cutting looks straightforward, but the right plywood and settings make all the difference - especially if you're working with fine details or tight curves.

In this guide, we’ll break down the easiest way to get clean, crisp die cuts using plywood, and why materials like TruFlat® Plywood make the whole process smoother for beginners and pros alike.

What Does “Die Cut” Mean in Laser Cutting?

Die cutting simply means cutting shapes with clean edges and smooth curves-kind of like cookie cutting, but with wood. For laser cutters, die cutting usually involves:

  • Small details

  • Sharp corners

  • Tight curves

  • Consistent edge quality

Because these cuts are precise, your plywood needs to be:

  • Flat

  • Consistent

  • Easy to cut

  • Free from voids

That’s exactly why many makers switch to TruFlat® when they want reliable results every time.

Here is where you can find the TruFlat Wood Series:
https://truflatplywood.com/collections/truflat-laser-plywood


Choosing the Best Plywood for Laser Die Cutting

If you’re learning how to cut plywood for die cut with a laser, the material you use is 70% of the final result. Here’s what to look for.

1. Extreme Flatness

Warped plywood will ruin die cuts because the laser loses focus, making edges uneven. TruFlat® has one of the best flatness tolerances in the industry, which is why die cuts come out crisp and accurate.

Explore flat, laser-ready sheets:
 https://www.truflatplywood.com/pages/wood-series


2. Zero or Minimal Voids

Voids inside plywood cause the laser to:

  • Struggle at certain points

  • Leave rough edges

  • Fail to cut through


3. Pre-Finished Surface

Die cuts often require clean faces because you may not be sanding or finishing afterward. TruFlat® comes pre-finished on both sides, which helps:

  • Reduce burn marks

  • Remove the need for masking

  • Make both surfaces look polished after cutting

Check finishes like Maple, White 2.0, Walnut, and Linen here:
https://truflatplywood.com/collections/truflat-laser-plywood

4. The Right Thickness

For laser die cutting:

  • 1/8" (3mm) plywood works best for delicate shapes

  • 1/4" (6mm) is better for sturdy dies, stands, or layered projects


How to Cut Plywood for Die Cut With a Laser (Step-by-Step)

Here’s the simple, beginner-friendly process.

Step 1: Choose a Flat, Laser-Ready Sheet

If your plywood is warped, even slightly, you’ll get uneven die cuts.
 This is why TruFlat® is ideal-it stays flat from corner to corner.

 See the Wood Series:
 https://www.truflatplywood.com/pages/wood-series

Step 2: Set Up Your Design Properly

Clean lines = clean cuts.

Tips:

  • Use smooth curves, not jagged paths

  • Close all paths

  • Use minimal nodes for cleaner edges

  • Test the design in cardboard first

Step 3: Dial In the Correct Laser Settings

There’s no one-size-fits-all, but here’s a good starting point for 1/8" (3mm) TruFlat plywood:

  • Cutting Speed: Medium

  • Power: High

  • Air Assist: ON

  • Passes: Usually 1 (sometimes 2 for thicker woods)

For 1/4" (6mm):

  • Speed: Slower

  • Power: High

  • Passes: 2

Always run a small test first!

Step 4: Use Air Assist for Cleaner Edges

Air assist helps blow away smoke and keeps your die-cut edges sharp instead of fuzzy or burnt. It’s a must for detailed cuts.

Step 5: Keep the Wood Secure and Level

If the plywood lifts or shifts, your die cuts won’t line up.
 Use:

  • Pins

  • Magnets

  • Honeycomb hold-downs

And always check that the wood is fully flat before cutting.

Step 6: Clean and Finish (Optional)

If you’re using TruFlat®, simply wipe the surface with a dry cloth-no sanding or sealing needed.
 If you’re using unfinished plywood, you may need:

  • A quick sanding

  • A light clear coat

  • Masking before cutting (only for raw wood)

Want to skip masking forever?
Choose pre-finished TruFlat:
https://truflatplywood.com/collections/truflat-laser-plywood

Tips for Cleaner Laser Die Cuts

1. Choose the Right Wood Grain Direction

Cutting with the grain = cleaner lines.
 Cutting against the grain = slightly more resistance.

2. Use Multiple Passes for Thicker Sheets

Sometimes cutting slow in two passes reduces char.

3. Keep Your Lens Clean

A dirty lens = weak laser = poor die cuts.

4. Use Vector Settings for Thin Lines

This keeps inner cuts sharp and uniform.

Best TruFlat Plywood Options for Die Cutting

Here are the top picks if you want the cleanest results:

TruFlat Maple

Amazing engraving clarity + smooth cutting.

TruFlat White 2.0

Perfect for décor and modern die-cut shapes.

TruFlat Walnut

Rich & premium look for finished products.

TruFlat Paint Plywood

Already primed for painting-great for craft dies.

If you want to test multiple types:
Try the TruFlat Starter Pack
https://truflatplywood.com/collections/truflat-starter-packs

Why TruFlat Makes Die Cutting Easier

If your goal is to learn how to cut plywood for die cut with a laser without dealing with unpredictable results, TruFlat® really simplifies the process:

  • Ultra-flat surface

  • Pre-finished both sides

  • Void-free core

  • Cuts cleanly in one pass

  • Beautiful designer finishes

  • Beginner-friendly

  • Works with Glowforge, xTool, Aeon, OMTech, Trotec, and more

It removes the biggest headaches makers deal with-warping, burn marks, uneven cuts, resin bleed, and sanding.

Start Creating Better Die Cuts Today

If you want clean edges, predictable results, and plywood that’s specifically made for laser cutting, TruFlat® is one of the easiest materials to work with.

Shop All Products
https://truflatplywood.com/collections/truflat-laser-plywood

Try a Starter Pack
https://truflatplywood.com/collections/truflat-starter-packs

Read More Blogs