Lit-Edge LED Acrylic Sign: CO2 Walkthrough

A 5×7" cast acrylic lit-edge sign with USB-powered LED base. Premium gift / décor item; sells $80-130 retail. Total time: ~20 minutes engrave + 10 minutes assembly.

The order

"Custom monogram lit-edge sign for my home, last name + small decorative graphic."

Materials

• 1× 5×7" cast acrylic (clear, 5-8mm thick) ($6-15)
• USB LED base (Amazon: ~$8-15) with slot matching acrylic thickness
• Soft cleaning cloth + isopropyl alcohol
• Optional: gift box for premium presentation

Step 1: design the file

1. Lightburn workspace at acrylic dimensions (5×7" or 127×178mm).
2. Place the customer's monogram or design centered.
3. Add small decorative element (botanical accent, geometric border).
4. Mirror the design horizontally: you're back-engraving. The design must be flipped to read correctly from the front.
5. Convert text to outlines so font isn't required.
6. Keep design within 80% of the acrylic dimensions, leaves clear margin for visual breathing room.

Step 2: customer proof

1. Show customer a NON-mirrored version (how it will look from the front when lit).
2. Verify spelling, layout, design choices.
3. Confirm acrylic thickness preference (5mm = subtle, 8mm = dramatic depth perception).
4. Wait for explicit approval. Save proof.

Step 3: prepare acrylic

1. Confirm cast acrylic, NOT extruded. (Cast gives clean engraved frost; extruded looks fogged matte.)
2. Peel paper masking from BOTH sides.
3. Wipe with IPA, removes manufacturer protective oils.
4. Place on bed. Some users mask the FRONT side again with painter's tape to protect from incidental smoke during engrave (back side stays exposed for the laser).

Step 4: focus and frame

1. Acrylic placed BACK SIDE UP on the bed (the side that will face the LED base when assembled).
2. Focus on the back surface (not the front).
3. Frame to verify the design lands within the acrylic bounds.

Step 5: layer settings (35-50W RF tube, 2" lens)

Layer	Mode	Settings
Tool layer (boundary)	Output OFF	,
Design (engrave)	Fill	Speed 400 mm/s, Power 30%, Interval 0.06mm, Air assist minimal

Keep air assist as low as your nozzle allows. High air rounds the engraved edges and the sign won't catch light cleanly. But fully off lets smoke deposit on the lens (and on the acrylic, which fogs the engrave). The right setting is "just enough flow to keep the lens clean. Never enough to round the engrave edges." On most lasers, that's the lowest setting where you still feel air at the nozzle.

Step 6: run engrave

1. Open Preview (Alt+P), verify time estimate (~15-20 min).
2. Press Start.
3. Engrave runs. The acrylic frosts where the laser hits, visible as a dull whitish texture against the otherwise clear sheet.

Step 7: post-engrave inspection

1. Wait for fume extraction to clear.
2. Remove acrylic. Wipe dust off with soft cloth.
3. Hold up to light at an angle, engraved areas should look frosted/etched.
4. Inspect from the front side: design should appear correctly oriented (since you mirrored it during design).
5. Look for any voids or skipped areas. If found, you may need to re-run.

Step 8: assemble with LED base

1. Take the LED base (slot up).
2. Slide the bottom edge of the acrylic into the slot.
3. Confirm fit is snug, should slide smoothly without forcing.
4. Plug the LED base into USB power.
5. Turn on. The engraved areas glow vividly while clear areas remain transparent. Magic.

Step 9: photograph + package

1. Photograph in dim lighting with LED base lit. The contrast against dark background sells the product.
2. Wrap acrylic in tissue paper.
3. Place LED base in original box; pack acrylic separately to prevent scratching during shipping.
4. Add hand-written note. Optional gift box for premium presentation ($3-8 add-on).
5. Ship in padded mailer.

Pricing breakdown

Materials (acrylic + LED base)	$15-22
Setup + proof	15 min × $80/hr = $20
Engrave time	18 min × $80/hr = $24
Assembly + testing	10 min × $80/hr = $13
Packaging	10 min × $80/hr = $13
Subtotal cost	$85-92
Markup (over cost)	+$15-40
Customer price	$100-130

Common pitfalls

• Engrave doesn't glow: air assist was on; rounded the engraved edges. Re-engrave with air OFF.
• Glow is dim: engrave too shallow. Increase passes or power.
• Edges are matte / fogged: used extruded acrylic. Switch to cast.
• Light leaks from sides: acrylic edges weren't laser-cut polished. Use freshly laser-cut acrylic with clean edges.
• Design appears reversed when assembled, you forgot to mirror during design. Re-engrave on a fresh acrylic.

Variations

• Multi-color RGB LED bases: premium tier ($25-50 base, sells for $130-180).
• Wood base + LED strip: custom wood (cherry / walnut / maple) with hidden LED strip channel. Sells $180-300.
• Stacked acrylic layers: two or three engraved sheets create depth. Sells $180-280.
• Photo etched acrylic: photograph engraved on acrylic + LED base. Most premium tier.