When a laser cutting machine is working correctly, it drives unmatched growth for your business. That’s because they efficiently and precisely make cuts, improving output and quality.
However, they can also undergo some common laser-cutting machine problems. When those happen, it can stall your operation, impact quality, and slow everything down.
That’s why Accurl is here to help you with troubleshooting laser cutting issues like poor cut quality, laser beam misalignment, software issues, and much more. Keep reading to resolve these issues with simple solutions.

The Most Common Laser Cutting Machine Problems
These are some of the most common problems you might experience with a laser-cutting machine. Some are more noticeable than others, but it’s good to know how to identify your problem before determining an effective solution.
Poor Cutting Quality
Poor cutting quality can negatively impact the outcome of every cut, creating rough edges, inconsistent depth, or larger heat damage. When this happens, you and your team might desperately search for how to improve laser cutting quality. So, what causes poor cutting quality?
There are a variety of different causes that commonly affect cut quality, but the most common are incorrect settings or material issues. That means that the settings are incorrect for the cuts you want, based on the material, thickness, or other parameters.
Another cause of poor cutting quality is lens contamination. That’s why it’s essential to clean and maintain your machine regularly, ensuring a clean lens and a high-performing machine with top-notch cut quality.

Laser Beam Misalignment
Another common issue is a laser beam misalignment. This can ruin the precision of a machine, even if you are using one of the most accurate cutting machines like the Accurl MasterLINE which uses a powerful fiber laser for exceptional precision.
So what can cause a laser beam to be incorrectly aligned? It can happen due to improper calibration, so make sure anyone who is using or calibrating your machine is properly trained, not only in laser cutting but for that specific model.
Additionally, beams can simply become aligned after using them often, which is why it’s important to calibrate and inspect often. Doing so can help you proactively address issues by fixing laser cutting errors before or immediately after they occur.
Overheating of Components

Laser cutting machines leverage powerful lasers at extreme heat to perform precise and efficient cuts, but when the machine itself starts overheating it can undergo damage and lead to costly repairs.
As soon as your machine starts overheating, the first thing you need to do is to stop using it. Then, look for causes like a lack of cooling fluid. Additionally, using the laser cutting machine for an extended period can cause overheating, and it might just need a break.
Material Compatibility Issues
Sometimes it’s not the laser cutting machine itself that develops a problem. It can also be the material. Whether you are using a material the laser cutting machine isn’t made for or simply low-quality materials, this can cause problems with the final outcome.
Always make sure you use quality materials that the machine is designed to accommodate. Then, make sure you set the correct parameters for those materials.
Software and Firmware Errors
Outdated or faulty software can impact your operation, leading to imprecise cuts, inefficient speeds, and a slow adjustment process. In addition, sometimes software simply messes up and needs to be recalibrated or restarted.

Step-by-Step Solutions to Fix Laser Cutting Machine Issues
Whatever problems you are having with your laser cutting machine, the experts here at Accurl are here to help with troubleshooting laser cutting issues. Simply follow the steps and you’ll be on your way to fixing laser cutting errors and restoring the performance of your machine.
For Poor Cutting Quality
- Check and clean the lens, checking for damage, debris, dust, and other contaminants.
- Adjust power and speed settings, making sure they are set to the type of material and cut. Different materials require different settings, on different machines.
- Use appropriate materials that the machine is designed to cut, then use the CNC controls to ensure the settings are correct.

For Laser Beam Misalignment
- Perform regular calibration checks. We recommend setting a daily, weekly, monthly, and yearly checklist, including calibration on the daily or weekly portion.
- Use a beam alignment tool, designed to ensure the beam is bounced around the materials onto the cutting surface.
For Overheating
- Ensure proper cooling systems are in place and any cooling fluids are properly filled.
- Schedule downtime to avoid overheating. Depending on the machine, this could be often or rarely, but it’s something that your operators should be aware of.
For Material Issues
- Always verify material specifications, checking the machine for the type of material and thickness before making another cut.
- Test on a sample before full-scale production to avoid wasting materials or causing damage to materials or the machine.
For Software Errors
- Update the software regularly. The frequency will depend on the type of software you use, but doing so can keep your machine running smoothly for years to come.
- Consult the manufacturer for troubleshooting laser cutting issues related to software, whether it’s having issues or simply outdated.
Preventative Maintenance Tips for Laser Cutting Machines
The most important thing you can do to ensure you don’t run into common laser cutting machine problems is to proactively maintain the machine. This type of preventative maintenance can extend the lifespan of your machine, prevent costly repairs, and guarantee the best accuracy, efficiency, and quality.
Here are some preventative laser cutter maintenance tips you should keep in mind:
- Clean the optics at least weekly, including the lens, mirrors, and any other components. They can get dirty fast, so it’s important to never miss a week.
- Check cooling systems daily and change the cooling water, inspect the pump, look for damage, see if there are leaks, and make sure the coolant levels are correct.
- Replace worn-out parts promptly, inspecting the machine daily for wear, tear, and damage. As soon as a part is worn out, order a new one to replace it.

When to Seek Professional Help for Fixing Laser Cutting Errors
While troubleshooting laser cutting issues isn’t too difficult, especially for common laser cutting machine problems, there are times when it would be best to seek professional maintenance, servicing, and repairs.
The first is if you notice significant performance issues that weren’t corrected by inspecting, cleaning, calibrating, or the other steps listed above. It could be a serious issue and the best time to fix it is immediately.
Another time to request professional technicians is when you are greeted with error messages regularly. These messages are there for a reason. Heed their warning and hire an expert.
Finally, unusual damage, visual damage, noticeable vibrations, and power fluctuations are all problems that could require a professional repair technician to resolve.
When you need a professional service, we recommend going with the manufacturer or a manufacturer-approved service provider. For example, Accurl offers ongoing maintenance, training, and repair services to ensure your laser cutting machine remains the best, fastest, and most precise in the industry for years to come.
Conclusion
Whether you are experiencing overheating, poor alignment, poor cut quality, or software issues, it’s important for you and your operators to know how to resolve common laser-cutting machine problems.
In addition, we strongly recommend implementing a preventative maintenance schedule, with daily, weekly, monthly, and yearly checklists. You can click here for a laser cutting machine maintenance checklist.