How to Upgrade Your Laser Engraver with Air Assist

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If you own a CO₂ laser machine, you’ve probably heard makers and professionals talk about adding air assist for laser engravers. But what is it exactly, and why should you consider an upgrade? In short, an air assist laser cutting system can dramatically improve cut quality, reduce char, and extend the lifespan of your machine.

1. What Is Air Assist for a Laser Engraver?

Air assist is a system that blows a steady stream of air directly into the cutting or engraving path. This airflow helps in several ways:

• Cleans the lens path: Keeps smoke and debris away from the laser beam.
• Improves cut quality: Removes char and soot from edges.
• Reduces fire risk: Limits flare-ups and hotspots during cutting.
• Extends machine life: Protects optics and reduces maintenance.

While many CO₂ laser engravers come with small aquarium-style pumps, they don’t provide enough pressure for demanding projects.

A compressor-based upgrade delivers higher PSI and better consistency, ideal for anyone who does a lot of cutting.

2. Why Upgrade to a Compressor-Based Air Assist?

Stock pumps are okay for hobby use, but serious makers often find them limiting. Upgrading to a compressor system for your laser engraver with air assist provides:

• High airflow for cutting: Essential for thick woods, acrylic, and other tough materials.
• Low airflow for engraving: Prevents soot from being blown into freshly engraved details.
• Cleaner finishes: Less sanding and post-processing.
• Integration with software: Automatic control in LightBurn for easy switching between high and low flow.

As Brandt explains, “If you’re doing a lot of cutting, you’ll want more airflow. A compressor setup just makes your cuts cleaner, faster, and safer.”

3. Tools and Parts You’ll Need

For a typical CO₂ laser air assist upgrade (example: Hydra 13), you’ll need:

• Compressor (capable of consistent airflow at adjustable PSI).
• OneLaser air assist module (valves, connectors, relays).

• Airline tubing and inline connectors.
• Dual regulators (for engraving and cutting PSI levels).
• LightBurn software (for integrated control).

4. How to Upgrade Your Laser Engraver with Air Assist

Step 1: Disconnect the Stock Solenoid

On the left side of the Hydra, you’ll find the original air solenoid connected to the RF tube chamber. Disconnect the airline hoses and replace them with a 6mm-to-6mm inline connector. This bypasses the stock pump system.

Step 2: Install the Relays and Wiring

Move to the right side of the machine where the control board is located. Attach the provided relays and connect them to the OUT4 and OUT5 terminals—these control low and high airflow.

• OUT4 = Low flow (engraving).
• OUT5 = High flow (cutting).

Also, connect the OV cable to ground and loop the L51/L52 terminals with the existing wiring. This setup ensures the machine can switch between air levels when commanded.

Step 3: Route the Cables and Airlines

Run the extension cable from the right side to the left side of the machine, threading it through the rear channel or sensor ports. Connect it to the external air assist module, then attach the airlines.

• Air In: From compressor to regulator.
• Air Out: From regulator to air assist module, then into the laser intake.

Step 4: Set PSI Levels for Engraving vs Cutting

Using dual regulators, set different PSI levels:

• Engraving: ~1–2 PSI for light airflow. Keeps soot down without blowing debris into engravings.
• Cutting: ~15–20 PSI (or higher for thick materials). Ensures clean cuts with minimal char.

Brandt recommends starting around 20 PSI for cutting and testing based on your material type.

Step 5: Integrate with LightBurn

The best part of this upgrade is seamless control through LightBurn.

• Toggle Air Assist ON in the layer settings → High Flow (cutting).
• Toggle Air Assist OFF in the layer settings → Low Flow (engraving).

This means you don’t have to manually adjust valves or switches—the software automatically commands the airflow level you need.

4. Benefits of a CO₂ Laser Air Assist Upgrade

Once installed, the difference is clear. Here’s what you’ll notice:

1. Cleaner Cuts: Minimal char, sharp edges, and less post-processing.
2. Consistent Performance: Air keeps debris away, ensuring smoother passes.
3. Faster Workflows: Higher efficiency lets you increase cutting speeds.
4. Safety Improvements: Reduced chance of flare-ups or fires.
5. Professional Results: Projects look more polished and require less sanding or touch-up.

5. FAQs

Q: Do I need air assist for engraving?

A: Yes, but use low PSI to avoid blowing soot back into the design.

Q: Can I just use a stock pump?

A: Stock pumps provide minimal airflow. For cutting thicker wood or acrylic, a compressor system is far superior.

Q: How do I know what PSI to use?

A: Test based on your material. Around 1–2 PSI works for engraving, while 15–30 PSI works for cutting.

Q: Does it work with all CO₂ lasers?

A: Yes, though wiring and controller compatibility may vary. Machines like the Hydra series integrate seamlessly with upgrade kits.

6. Why the OneLaser Machine Is Ideal for Air Assist

The Hydra series and X series was designed with upgrades in mind. Adding a compressor-based CO₂ laser air assist upgrade is straightforward thanks to:

• Built-in relay compatibility.
• Easy access panels for wiring and airlines.
• Large work areas suited for heavy cutting projects.
• US-based support from OneLaser engineers.

Whether you own the Hydra 7, Hydra 9, Hydra 13, or Hydra 16, upgrading to a laser engraver with air assist will take your production quality to the next level.

Final Thoughts

Upgrading your laser engraver with air assist is one of the smartest improvements you can make. Whether you’re cutting thick wood, engraving fine details, or running your machine for business, the benefits are undeniable—cleaner cuts, safer operation, and faster workflows.

With the OneLaser Hydra upgrade, you can integrate compressor-based airflow, dual PSI regulators, and LightBurn controls all in one streamlined system. It’s not just about upgrading your machine—it’s about upgrading your results.

👉 If you’re serious about laser engraving, don’t wait. Add air assist and see the difference in your projects immediately.