How does the VCarve Pro & Aspire Laser Module work: toolpaths, power/speed settings, engrave vs cut strategies?

Overview

The Laser Module is a paid add-on that adds laser-specific toolpaths alongside the standard CNC toolpaths. The product page says it can be purchased as an add-on to Cut2D, VCarve or Aspire version 11 and later. It lets you design hybrid projects where some elements are CNC-machined and others are laser-cut or laser-engraved, all managed and simulated in the same software. The features are not included by default.

Installation: buy the module, then enter the license code with Help > Enter License Code. Restart the software to enable the features.

This entry is the overview. For every field on the forms, see the Laser Cut and Fill entry, the Laser Picture entry, and the entry on adapting a post-processor for lasers.

The Laser Toolpaths

1. Laser Cut and Fill

Cuts out shapes or marks areas. Cut-outs can take the kerf (the width of the laser beam) into account so the finished part keeps the size of the vector.

Four strategies:

• Cut Outside / Right: the laser runs around the outside of the selected vectors (or along the right-hand edge of open vectors), automatically offset by the kerf width. The part's outside dimensions match the vector. Use it to cut parts to size
• Cut Inside / Left: the laser runs around the inside (or left-hand edge), allowing for kerf. The remaining recess matches the vector. Use it for holes, slots and sockets
• Cut On: the center of the laser beam runs along the vector, with no kerf compensation. Use it for score lines and detail marks
• Hatch Fill: a marking or shading strategy that profiles the vectors and fills the shapes with stripes

Key settings:

• Power: the proportion of your machine's maximum laser power to use
• Move Speed: the maximum speed during cutting or engraving moves. Slower generally means more heat, so a darker mark or deeper cut
• Cut Depth, No. Passes and No. Repeats: No. Passes is worked out automatically (Cut Depth divided by the laser's Pass Depth), so you cannot edit it. No. Repeats runs the same toolpath again, for when your laser cannot achieve a full burn in one go
• Overscan: lets the laser head travel past the edge of the area with the laser off, to account for deceleration that would otherwise darken the edge. It depends on the machine, so run test images to find how much your machine needs at a given feed rate
• Allowance: extra offset for Cut Outside and Cut Inside, for easing or tightening the fit without changing the kerf setting

Hatch Fill settings: Stepover (spacing between hatch lines), Hatch Angle, Cross Hatch (a second set of lines for a denser fill), Fill Together or Fill Regionally, and Outline.

2. Laser Picture

Etches a copy of a selected bitmap into the material by varying the laser power across the image to reproduce light and dark areas.

Strategies:

• Raster: a single set of parallel lines (stripes) across the image
• Hatch: two sets of lines at 90 degrees. This usually gives a denser image but typically takes twice as long
• Selected: uses the vectors you have selected as the pattern for the toolpath moves

Dither Image: unchecked, the laser power changes evenly with the light and dark areas of the image, using continuously varying power (the higher quality method). Checked, the tones are made with black dot patterns of differing density. Use dithering only for materials that burn in just two tones, burnt or unburnt.

Line Spacing: tight stripes give a denser image but take much longer. The densest setting is set by the kerf of your laser beam, and the sparsest is 30 times that value.

Line Angle: 0 degrees gives horizontal stripes and 90 degrees vertical.

3. Laser Sketch Engraving

Applies the sketch carving technique to generate a laser toolpath from an image or model. It picks out the key details instead of filling the whole image, which gives a stylized result with less burn time.

Engrave vs. Cut: Strategy Guide

The power and speed values below are only starting points to test on scrap, because they depend on your laser and material.

The fundamental rule: power and time together set the energy delivered. For a similar effect, a higher power allows a higher speed, and a lower power needs a lower speed.

Simulation Calibration

A laser toolpath simulation does not remove material. It marks the surface of the simulation model to simulate charring. To match the simulation to real-world results:

1. Cut a sample with the material and power settings you typically use
2. In the Tool Database, adjust the laser tool's Maximum Burn Rate. This is the maximum speed at which the tool, at 100% power, will still burn the material
3. A greater value makes the simulated toolpath look darker
4. Adjust until the simulation matches your actual result

Power Control Requirement

Laser toolpaths output a power setting from 1 to 100%, and the post-processor formats it for your controller. Older post-processors do not work correctly with the Laser Module. A post-processor must be laser capable (marked with LASER_SUPPORT="YES"). The product page lists the machines and controllers supported at launch, which are mostly GRBL-based. See the entry on adapting a post-processor for lasers for the steps.