How to Make Custom Enamel Pins with a 60W Fiber Laser

This guide details the complete workflow for creating custom enamel pins from scratch using a fiber laser. 

Setup & Materials

• Laser: 60W JPT MOPA 
• Material: 1mm Brass sheet
• Enamel: Pébéo Ceramic (cold solvent-based enamel)
• Chemicals: Citric acid, baking soda, white spirit, rubbing alcohol
• Abrasives: 600, 1200, and 2500 grit wet sandpaper
• Finishing: UV rubber gel top coat (UV lamp, 99s) or 2-part doming epoxy
• Tools: Fume extractor, insulin syringes, pin posts, butterfly clutches

1. Design Preparation

• Prepare vector artwork with closed paths to act as walls for the enamel.
• Remove stray nodes and overlapping lines.
• Keep outer cut lines on a separate layer.
• Ensure lines are thick enough to hold enamel.

Pro Tip: Set the outer cut line as a separate boundary layer, not part of the engraving design.

For reference on image engraving techniques on metals, see 60W Fiber Laser Image Engraving Stainless Steel Settings.

2. Software Setup (LightBurn)

• Import vectors and scale appropriately.
• Separate layers for:
  1. Deep engraving (enamel recesses)
  2. Cleaning pass
  3. Cutting
• Preview carefully to verify engraving depth and cutting paths.

For more advanced laser workflows, check Laser Tips and Tricks.

3. Laser Parameters

A three-step laser process is recommended: Deep Engraving → Cleaning → Cutting.

Deep Engraving (Fill)

• Speed: 2500 mm/sec
• Power: 95%
• Frequency: 45 kHz
• Q-Pulse Width: 500 ns
• Line Interval: 0.05 mm (508 DPI)
• Angle Increment: 37°
• Settings: Cross-hatch ON, Auto-rotate ON
• Passes: 35

A slight micro-texture at the bottom improves enamel adhesion. Avoid overheating the brass to prevent warping.

Cleaning Pass (Fill)

• Speed: 5000 mm/sec
• Power: 30%
• Frequency: 40 kHz
• Q-Pulse Width: 200 ns
• Line Interval: 0.03 mm (846 DPI)
• Settings: Cross-hatch ON
• Passes: 1

Cutting (Line)

• Speed: 100 mm/sec
• Power: 95%
• Frequency: 20 kHz
• Q-Pulse Width: 500 ns
• Settings: Wobble ON (Step: 0.05, Size: 0.15)
• Passes: 31

Cutting 1mm brass typically requires 30+ passes for a clean finish.

4. Pickling (Acid Cleaning)

• Submerge pins in warm citric acid and stir gently.
• Neutralize in water + baking soda.
• Dry with a lint-free cloth.

This process removes oxidation and laser soot. Avoid overexposure in acid.

5. Enamel Application

• Fill recessed areas with cold Pébéo Ceramic enamel using insulin syringes for precision.
• Apply in a single pass without layering or overfilling.
• Work in a ventilated area due to enamel toxicity.

6. Curing

• Place pins on a flat surface and allow 1–3 days for full polymerization and hardening.

7. Wet Sanding (Ice Water Hack)

• Progressively wet-sand using 1200 → 2500 grit until brass walls are flush and shiny.
• Use ice-cold water to prevent friction heat from softening enamel.
• For gray smudges caused by brass dust, wipe with white spirit and wash immediately with soap.

8. Doming & Top Coat

• Clean pins with alcohol.
• Quick finish: apply UV rubber gel top coat and cure 99s under a UV lamp.
• Premium finish: apply clear 2-part doming epoxy.

9. Attaching Hardware

• Use 2-part epoxy glue to attach pin posts to the back; cure 24 hours.
• Attach butterfly clutches. Pins are now complete.

Final Notes

• Layering, DPI, and pulse control are critical for achieving precise designs.
• This workflow allows consistent production of high-quality enamel pins.