How to Laser Cut Tray Projects with Precision and Style

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A laser cut tray is a great project for beginners to intermediates who want to turn plain plywood into beautiful and useful decorations or gifts. Laser engraving and cutting let you make exact, repeatable results with a little bit of personalization, whether you're making a bourbon flight tray, a decorative catchall, or a serving tray.

1. Why Create a Laser Cut Tray?

Laser cut trays are more than just beautiful—they’re versatile. They can be used for:

• Serving snacks or drinks
• Displaying products in small businesses
• Organizing everyday items at home
• Selling as gifts on Etsy or at local craft fairs
• Promotional items for events or whiskey/bourbon tastings

Best of all, once you’ve got the right machine and materials, you can batch produce them with high precision and low waste.

2. What You’ll Need to Laser Cut a Tray

Before you start, here are the materials and tools you’ll need:

Materials:

• ✅ 3mm Plywood Sheet (Baltic birch or similar high-quality plywood)
• ✅ "Bourbon Flight Tray" Cutting File (SVG/DXF file with engraving and cut layers)

Equipment:

• LightBurn Software – For layout, setting power/speed, and sending to the machine
• OneLaser XRF Laser Engraver – CO₂ laser cutting machine with autofocus
• Cloth or masking tape – To clean the plywood or reduce burn marks

3. Step-by-Step: How to Laser Cut Tray Projects

Let’s dive into the process of making your own laser cut tray, from file setup to final assembly.

Step 1: Clean and Prepare the Plywood Sheet

Wipe down the 3mm plywood with a clean, dry cloth to begin. Dust and oils can change how well the engraving looks.

Before engraving and cutting, you can put masking tape on the wood's surface. This helps keep scorch marks to a minimum and makes cleaning up after the job easier.

Put the plywood flat on the working bed of your OneLaser XRF. Make sure it is securely in place and won't move while you are cutting or engraving it.

Step 2: Import the Tray File and Set Your Parameters in LightBurn

Open LightBurn and import your Bourbon Flight Tray file. Ensure the cut and engrave layers are assigned to the correct colors/layers in the software.

✅ Engraving Settings:

• Speed: 600 mm/s
• Max Power: 40%
• Min Power: 10%
• DPI: 300

These engraving settings are perfect for 3mm plywood and will give you clean, legible text or artwork with moderate depth.

✅ Cutting Settings:

• Speed: 10 mm/s
• Max Power: 95%
• Min Power: 90%

These settings will fully cut through 3mm plywood in one pass using the OneLaser XRF. Make sure you run a quick test cut on a scrap piece to verify performance.

Step 3: Adjust the Auto Focus

Use the autofocus feature on your OneLaser XRF touchscreen to set the perfect height for engraving and cutting.

Why It Matters: A well-focused beam ensures your cuts go cleanly through and your engravings are crisp and accurate.

Once focused, frame your design in LightBurn to make sure it fits your material placement perfectly.

Step 4: Send the Job to Your Laser and Watch the Magic

When you hit start, the laser will first engrave and then cut. Pay attention to ventilation, especially if you're working inside. Plywood can make light smoke and smell.

When the laser is done, you'll see that the base, sides, and cutout slots of the tray are all ready to be put together.

Step 5: Assemble the Laser Cut Tray

Once the job is done:

1. Remove masking tape (if used) and gently sand edges if needed.
2. Fit the joints together. Most laser cut trays are designed with interlocking tabs, so no nails or screws are needed.
3. Use wood glue for a more permanent hold.
4. Clamp or hold in place for 5–10 minutes until set.

That’s it—you’ve made your very own laser cutting tray with clean lines, smooth edges, and personalized details!

3. Popular Variations of Laser Cut Trays

Once you master the basics, try branching out into different tray designs to expand your product line or impress your clients:

Wine Tasting Flight Trays: Add round holes for glasses and etch the names of the wineries or vineyards.

Decorative Candle Display Trays: Perfect for home décor shops. Use floral engravings or geometric patterns.

Gift Box Trays: Make engraved trays that double as keepsake boxes—great for weddings or anniversaries.

Corporate Swag Trays: Engrave a company’s logo and pair it with snacks or promotional items.

Cheese Boards and Snack Trays: With food-safe finishes, these can be both functional and elegant.

Gaming Dice Trays: Perfect for tabletop gamers (D&D, Warhammer, etc.). Design trays with engraved grid lines, compartments for dice, and custom initials or game logos.

Coffee Station Organizer Trays: Create multi-compartment trays to hold sugar packets, creamers, stirrers, and pods. Add engraved coffee quotes or café branding.

Spa and Bathroom Trays: Craft elegant trays for candles, essential oils, or bath salts. Use bamboo or waterproof-sealed plywood with floral or minimalist engravings.

Dinner Party Serving Trays: Design large, sturdy trays with handles to serve appetizers or drinks. Engrave the family name or a witty quote like “Eat, Drink, Repeat.”

Kids’ Craft Supply Trays: Organize crayons, paint, or small tools with a tray that includes sections and fun engraved patterns (stars, rainbows, animals).

Jewelry Display Trays: Use felt-lined or slotted compartments to hold rings, necklaces, and earrings. Great for handmade jewelry sellers or boutique owners.

Succulent and Plant Display Trays: Design trays to hold mini pots or propagation stations, with engraved botanical patterns or plant names.

Puzzle Assembly Trays: Create flat trays with raised edges and compartments to help puzzle enthusiasts sort and assemble pieces.

Holiday-Themed Trays: Offer seasonal tray designs like:

• 🎄 Christmas cookie trays (with “Santa’s Cookies” engraving)
• 🦃 Thanksgiving snack trays
• 🎃 Halloween treat sorters

Great for gift bundles or pop-up markets!

Personalized Desk Organizer Trays: Laser cut and engrave nameplates, pen slots, business card holders, and phone stands all within a compact desk tray. Ideal for students, WFH professionals, and corporate gifts.

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4. Materials You Can Use for Laser Cut Trays

Material	Notes & Use Cases
Plywood	Most popular for trays. Affordable and sturdy.
MDF	Smooth engraving but more fragile than plywood.
Acrylic	Modern, sleek look. Ideal for minimal designs.
Leather Accents	Add handles or inserts for premium feel.
Hardwood Veneers	For high-end serving trays or décor pieces.

5. Tips for Cleaner, Better Laser Cut Trays

• Use high-quality plywood: Cheap plywood can contain glues or voids that mess up cuts.
• Test your settings: Material batches may vary—run small test cuts.
• Mask your wood: This reduces burn marks and cleanup.
• Design with joints in mind: Finger joints and tabs work best for sturdy tray builds.
• Offer customization: Names, initials, or logos make your trays more desirable for gifting.

Learn more: How to Choose the Best Wood for Laser Engraving?

FAQs

Q: Can I use thicker wood than 3mm?

Yes, you can use 4mm–6mm plywood or hardwood if your laser is powerful enough. Just adjust the cutting speed and possibly use multiple passes.

Q: Is the OneLaser XRF suitable for cutting trays?

Absolutely. The OneLaser XRF is a CO₂ laser with fast engraving speed, high accuracy, and excellent cutting performance for wood, acrylic, and more. Its built-in autofocus and LightBurn compatibility make it perfect for detailed laser cut tray projects.

Q: How long does it take to cut a tray?

It depends on the complexity and size. A simple tray with light engraving takes around 10–15 minutes, including setup. Larger or highly detailed trays may take up to 30 minutes.

Q: Can I sell laser cut trays?

Definitely! Personalized trays are in high demand for gifts, weddings, bourbon flights, and business branding. You can sell them on Etsy, Shopify, local craft markets, or your own website.

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Final Thoughts

Making your own laser cut tray is a fun and useful project, whether you love laser cutting, sell things on Etsy, or are a creative DIYer. All you need to make beautiful, useful trays that impress every time is a 3mm plywood sheet, a ready-made file, and your OneLaser XRF machine.

Explore the OneLaser X Series!

There are so many things you can do with them, from bourbon flight trays to home decor displays. Once you get the hang of this simple process, you'll want to make even more one-of-a-kind laser-cut trays and boxes for every event.