This Special Project Started with Just an Idea…
- heidi8013
- 6 days ago
- 5 min read
and a Whole Lotta Aesthetic Vibes ♥
5mm Clear Casted Acrylic featuring softball players
When we say your CO2 laser can do just about anything…we mean it...even the small things.
As a mom of 3 teenage girls (aka professional aesthetic experts), I knew exactly what I wanted to make when our youngest daughter’s middle school softball season started wrapping up.
This year, there are 6 eighth-grade girls graduating from the team — and we wanted to send them off with something more personal than a trophy... something fun, something aesthetic, and definitely something that lights up.
That’s when the idea for these custom acrylic LED lights came to life!
We designed and created these on our Phantom Photon PP-3523 90 watt CO2 laser. The final result? A totally custom keepsake for each player — and a really fun way to show what’s possible with just a little creativity (and the right tools).
Here's what we love about this project:
→ Thoughtful & personalized
→ Budget-friendly but high-impact
→ Perfect use of acrylic & LED lighting
→ Made with love and laser power
Whether you’re a business owner, hobbyist, or just a proud parent like me — your next project idea might be closer than you think.
How did I do it? See below!
First Step: Design It Your Way
Every great project starts with an idea — and then it’s time to bring that idea to life. When it comes to designing for your Phantom CO2 Laser, you can design in the program you feel most comfortable. Our lasers are set up to work seamlessly with Lightburn — an easy-to-use design software perfect for beginners and pros alike.
Lightburn supports these file types:
→ .AI
→ .SVG
→ .DXF
→ .JPG
→ .PNG
→ .BMP
Whether you’re creating something from scratch or bringing in an existing design, Lightburn makes it simple to get your project ready for the laser.
Step 2: Material Used
For this project, I went with clear 5mm cast acrylic — and there’s a good reason for that! When it comes to engraving acrylic, cast acrylic is always the way to go.
Why? Because it reacts better with the laser, giving you a nice, bright, frosty white engraving that really pops — especially when you add LED lighting.
(Fun fact: Extruded acrylic tends to engrave more clear or almost invisible, which isn’t ideal if you want that bold, standout look.)
Cast acrylic is also super easy to cut cleanly on the Phantom Photon PP-3523 — making it perfect for projects like custom LED lights, awards, or signs.
Step 3: Lightburn Settings
Honestly — the hardest part of learning lasers isn’t the machine itself (that part’s pretty straightforward). It’s dialing in your feeds and speeds.
Just like most millennials (insert eye roll), I headed straight to YouTube University when I first started working with lasers.
Once I brought my artwork into Lightburn, I spent a little time organizing what parts needed to be engraved and what parts needed to be cut.
Pro Tip:
→ Always set your layers to engrave first, then cut.
→ In Lightburn, the order runs top to bottom in your layer list.
Another Quick Note:
→ Fill = Engrave
→ Line = Cut
Here’s what worked for me on this project:
→ Engraving: 300mm/s @ 18% power — No Air Assist
→ Cutting: 5mm/s @ 90% power — Air Assist ON
Step 4: Get Laser Ready
Okay… I know some of y’all are gonna think I’m crazy and/or a wimp — but let me tell you — one good flashback from an acrylic flare-up will scare the daylights out of ya… well, it did me anyway. 😂
So now, I always take a few extra steps to play it safe (and protect my project).
Here’s my setup routine:
• Double up a few wet paper towels and lay them down on the honeycomb bed.
→ This helps absorb any extra heat or flashback.
• Place a few 1" magnets on top to help hold them in place. Then, lay your acrylic on top of the magnets.
→ Don’t forget to remove the protective film from the side you’re engraving — but leave the film on the other side to prevent scratches while cutting.
• Next — and this is an old-school trick — I wipe a super thin layer of dish soap over the engraving area. → Why? It helps reduce smoke stains and keeps your acrylic looking crystal clear after engraving.
Step 5: Focus & Fire It Up
Alright — we’re in the home stretch! Now it’s time to get that laser focused and ready to roll.
Here’s what I do:
• Hit that Auto Focus button — let the machine do its thing and get dialed in. Set your Origin (this is basically telling the laser where to start).
• Then... my favorite little safety check — hit the Trace button on the controller.
→ This will outline exactly where your design is going to engrave or cut so you can double-check placement before committing.
Once everything looks good → close that lid → hit start → and let the laser magic happen!
BUT LISTEN...
This is NOT the time to go refill your coffee, fold a load of laundry, or get lost scrolling TikTok.
→ Never leave your laser running unattended. Fires happen FAST and nobody’s trying to be that person who set the building on fire because they weren’t paying attention. Stay close. Watch your job run. And get ready for that final product glow-up.
Step 6: The Final Product ✨
And just like that… we’ve got ourselves a finished project!
Once the machine is done doing its thing (and you’ve successfully avoided burning down the building — gold star for you, by the way ⭐), it’s time for the best part… the reveal.
Carefully remove your acrylic from the bed, peel off that protective film from the back (SO satisfying, right??), and run under some water to remove the dish soap...
And BOOM!
Look at you out here making customized, aesthetic, Pinterest-worthy acrylic LED lights like a total boss.
A quick little recap:
• We designed it.
• We picked the right material (cast acrylic for the win).
• We dialed in our settings.
• We prepped our laser like a pro.
• And now we’ve got a finished piece that’s ready to shine.
Literally.
Final Thoughts from a Laser-Lovin’ Mom:
This project was extra special for me because these lights were for my daughter and her 8th grade softball teammates. Getting to create something meaningful and show off what our Phantom Photon PP-3523 90 Watt laser can do - Total win-win.
Projects like this are exactly why I love what I do.
Moral of the story?
Lasers aren’t just for big businesses or production shops — they’re for moms, makers, creators, and anyone who loves turning an idea into something unforgettable.
Ready to make your own?
Come check us out at Phantom — let’s get you creating!
♥ Heidi
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