Laser Cutting
Machine Safety

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Laser Safety - Understanding the Basics

Industrial lasers are classified into 4 different categories.

Laser Class	Description	Hazards & Warnings
Class 1 / 1M	Normally safe under reasonably foreseeable use. Class 1M lasers are safe for unaided eye viewing but may be hazardous when using magnifying aids.	Little risk under normal operation. Avoid using binoculars or telescopes in the beam path.
Class 2 / 2M	Emit visible light (400–700 nm). Class 2 lasers are safe for skin but may be hazardous for the eye if viewed continuously. Class 2M lasers exceed Class 2 emission limits but are normally safe because of beam divergence.	Do not stare into the beam and do not use optical viewing aids. Terminate the beam on a non-reflective surface and avoid continuous viewing.
Class 3R / 3B	Class 3R lasers have accessible emission limits just above Class 1 or 2. The risk of eye injury is low for accidental exposure but hazardous for deliberate viewing. Class 3B lasers are hazardous to the eye and can damage skin at higher outputs.	Prevent continuous viewing, aim beams away from eye height, prohibit optical viewing aids, install controls to restrict access and provide beam stops.
Class 4	Lasers with emission levels above Class 3B can cause eye and skin injuries from both direct beams and diffuse reflections, which may ignite materials.	Require comprehensive controls, including controlled areas, interlocks, beam enclosures, warning signs, personal protective equipment (PPE) and trained operators.

Laser cutting machines are classified as Class 4 lasers

Laser cutters emit very high power levels and can even diffuse reflections, which can cause eye or skin injuries. Additionally, its beam may ignite materials, which classifies it as a class 4 laser. Even hobby users should undergo training or seek professional guidance before using the machine.

In Australia and New Zealand, laser safety is governed by the AS/NZS IEC 60825.1 and AS/NZS IEC 60825.14 standards.

General Safety Requirements When Operating Laser Cutting Machines

If you’re using a Class 4 high-power fiber laser, the following requirements apply:

Enclosures and interlocks

Laser cutting machines must have protective enclosures around the work area. Safety interlocks prevent laser operation when the enclosure is open or when a fault is detected. Emergency stop buttons should also be present.

Ventilation and fume extraction

Cutting certain materials produces toxic fumes. Proper ventilation, fume extraction systems, and fume treatment sized for the materials and airflow rates are required.

Personal protective equipment

Operators must wear laser safety eyewear and appropriate clothing. Respiratory protection may be needed when cutting materials that emit hazardous fumes.

Operator training

Operators must be trained on both the equipment-specific safety procedures and general laser safety principles. Training should cover machine setup, parameter selection, material suitability and emergency shutdown.

Safety signage and restricted access

Warning signs, restricted access areas, and documented emergency procedures must be visible to ensure personnel understand hazards and responses.

Regular audits and maintenance

Scheduled safety audits and equipment maintenance must be conducted to maintain compliance and ensure that interlocks, ventilation, optics, and cooling systems function properly.

Material compatibility and parameter control

Operators must follow manufacturer guidelines to select safe materials. Avoid PVC, vinyl, and other substances that emit toxic gases when cut. Set the correct power, speed, and focus parameters for each material, and record the settings.

Housekeeping and fire safety

Keep laser cutting areas clean, remove flammable materials, have a fire extinguisher nearby, and never leave the machine unattended during operation. Always provide a well-ventilated workspace and a stable surface for the machine.

Establishing a Controlled Area for Class 4 Laser Use

Restrict access and prevent unauthorised personnel from entering the laser area.

Laser beam paths should be short, enclosed, and positively terminated on appropriate beam stops.

Lasers should be operated in rooms without windows or permanently covered windows.

Use adequate post warning signs. Label on laser equipment and entrances, as well as outside the laser room.

Keep control of reflections by avoiding mirror-like surfaces and non-reflective materials.

Operators should wear laser safety eyewear matching the optical density to the laser's wavelength and power.

Operators must be trained on laser safety, operation, risks, and emergencies, with training records kept.

A medical examination by a practitioner must be performed immediately in the event of an injury or suspected injury.

Managing Risk and Laser Safety Documentation

All laser operators should have the right risk management processes and documentation in place before handling any Class 3 or 4 fibre laser.

Risk assessment should be carried out, including evaluation of the laser’s suitability, its capability to injure, the environment, potential hazards, and the required training.
Organisations should keep a register of all lasers used on site
Written safe work procedures must list hazards, conditions for use, and required controls for each laser.
Each laser must have labels. Areas using Class 3 and 4 lasers must clearly identify the responsible person and contact details.
Under Work Health and Safety Regulations, employers must ensure lasers pose no health risks and implement controls beyond the minimum standard if the risk assessment indicates additional measures are needed.

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