What is rotary engraving?

Discover everything you need to know (and why you should care) about rotary engraving. This article explores all aspects of the technique from machines and tools to the materials you can use. Find expert tips and ideas for rotary engraving applications here.

Rotary engraving refers to a type of engraving that uses rotating and sometimes non-rotating tools to mark and/or cut into compatible materials. It’s a timeless method of embellishing items and materials, and while it’s a classic form of fabrication, it’s certainly not an outdated technique.

What sets rotary engraving apart is the way material is marked or cut, utilizing a physical bit rather than a beam of light such as with laser technology. In short, rotary engraving differs from other types of engraving because it uses physical contact and removal of the material to carve and sculpt the material rather than a focused laser beam of light to vaporize the material. Physical contact makes the rotary engraving and cutting technique ideal for a broad range of materials and projects requiring deep and precise cuts because you don’t have to worry about the possibility of fumes off-gassing, material warping, or messy and time-consuming material preparation. Plus, the mechanical process allows the fabricator more control when working on a job. More material types can be fabricated with a rotary engraving system such as materials containing PVC, which are otherwise hazardous and not compatible with laser engraving systems. Rotary engravers can also introduce a “third dimension” to your projects by utilizing bevels on the edges of cut shapes and engraved areas.

How does rotary engraving work?

The way rotary engraving works is what makes it so special! Before we get into the details, let’s identify the major parts of a rotary engraving machine. These key parts include the spindle, engraving depth micrometer, engraving tool (aka bit or cutter), nose cone, work bed, and chip removal system.

A spindle is the device that holds and allows the cutter, or engraving tool, to spin at extremely high RPM’s during the engraving/cutting process. The engraving tool is a special cutting device that has specific shapes and angles on the tip to achieve the desired engraving or cutting path on the material. Engraving tools are available in a multitude of specialized shapes, sizes, and tip widths. Tool types may also be differentiated by the material type in which they are designed to be used. For example, you will likely need different tool types for engraving and marking plastic and metal.

Once the right bit for the job is chosen, it inserts into the spindle. Most spindles are “top-loading”, meaning the tool is inserted at the top of the spindle. Material is laid onto the work bed. The engraving tool must first be “zeroed” to the surface of the nose cone. Then the engraving depth is set by adjusting the engraving depth micrometer. The job is sent to the engraver and when the spinning tool makes physical contact with the material, it creates a mark or cut line.

The speed (or rounds per minute (RPM)) of the spinning tool and depth setting of the micrometer determines the depth of the engraving. The engraving depth can be controlled physically by the nose cone touching the material, or manually or by using a pre-programmed depth setting which usually does not rely on the nose cone touching the material. The ability to utilize specific tools, control spindle speed, and adjust feed rate and engraving depth are what make rotary engraving so versatile and valuable.

It's also important to note the importance of a chip removal system. The chip removal system pulls out the engraved chips or pieces while the cutting or engraving job is running. Normally, the chip removal system is activated automatically when the engraver first begins an engraving or cutting job. However, it can also be manually activated.

The ability to control the depth of a cut is particularly helpful when creating projects that must meet specific standards, like ADA-compliant signage. The American’s with Disabilities Act, or ADA, is a law that calls for raised lettering and braille on signage which must meet specific tactile and visual standards.

In addition to making ADA-compliant signage, rotary engraving offers the ability to create more durable signage than some other technologies due to the depth of engraving it can produce. The depth of the engraving makes signage less susceptible to fading or wearing over time , even when exposed to harsh conditions, frequent handling or in high-traffic areas.

What materials can you engrave with a rotary machine?

Another key benefit of using rotary engraving over another engraving process is the broad range of compatible materials that can be fabricated. Rotary engraving can be paired with most soft metals like brass, aluminum, as well as harder metals such as stainless steel without requiring a special coating or spray. In addition, rotary engraving can be used on wood, plastic, and acrylics!

Some materials, particularly certain metals, don’t fabricate well using CO2 laser engraving but are easily and effectively engraved using rotary tools. This flexibility makes rotary engraving a great choice for industrial applications, jewelry customization, and other projects requiring diverse material compatibility.

It's also important to note that because rotary engraving doesn’t produce nearly as much heat as laser engraving and other engraving methods, fabricators can worry less about warping, discoloration, and other problems that can occur with heat sensitive materials. Rotary engraving, as a mechanical process, does not produce heat, which helps preserve the natural finish and integrity of the material. This makes it an excellent option for engraving delicate or heat-sensitive items, such as certain plastics or fine metals, without compromising their appearance or structural integrity. However, it is important to note that when engraving hard metals, such as stainless steel, it may be necessary to utilize a liquid cooling system due to the high friction that occurs when fabricating this material.

What shapes can you create with rotary engraving?

The capability to control the speed, depth, and cutting geometry allows rotary engravers to create intricate and customized cuts that may not be possible with other engraving methods. Notable rotary engraving capabilities include beveled edges of various shapes, or multi-layered designs, all of which add a professional and unique aesthetic to the finished product. Additionally, rotary engraving tools can cut through materials entirely while simultaneously creating beveled edges if desired, allowing for the creation of complex shapes and patterns in a single operation.

Is it worth it to buy a rotary engraver?

We certainly think so! Adding a rotary engraver gives fabricators the capability to create durable, tactile, and dimensional elements on a broad range of materials. As we uncovered, the carvings and designs are created through a mechanical process that makes them more resistant to wear and tear than some other technologies. This durability paired with the possibility of beveled edges and marking on uniquely shaped surfaces makes rotary engraving a flexible technology suitable for projects like industrial signage that will face harsh conditions and frequent handling or cleaning.

So, we hope you’ll give rotary engraving a chance to win you over! It can achieve results that other types of engraving cannot, thanks to its ability to create deep, durable, and tactile designs; its compatibility with a wide range of materials; and its capacity for precise cutting, shaping, and engraving on uneven surfaces. Whether for industrial purposes, aesthetic applications, or compliance with specific standards, rotary engraving remains a powerful and versatile tool that stands out in the world of engraving and marking technologies. Ready to get started?

Best Rotary Engraving Machines for Beginners

We recommend the Vision line of rotary machines. For someone just getting started, the Vision Express S5 Desktop Rotary Engraver is a great option with an accessible price point! The machine will offer all the capabilities discussed here, with a small footprint of only (W x D x H) – 9.5" x 17.5" x 17.5" and a 6” x 8” work area.

Key Takeaways

• Key Benefits of Rotary Engraving

• Depth Control
• Pressure control
• Broad material capabilities
• Capability to create ADA signage
• Durable engraving
• Specialty cutter options
• Ability to create beveled edges and designs with dimension

• Compatible Rotary Engraving Materials

• Metals
• Wood
• Acrylic
• Plastic
• and more!

• Capabilities and Applications for Rotary Engraving

• Industrial and architectural signage
• Industrial tags
• Solar placards
• ADA-compliant signs
• Interior and exterior informational and wayfinding signage
• Signs and placards with beveled edges
• Creative projects

If you choose to work with Johnson Plastic Plus when starting your rotary journey, our customer success team will be here to guide you every step of the way. In addition, we’ve put together a list of tips for creating successful rotary engraved projects. Shape

Tips for Successful Rotary Engraving

• Select the right bit!
• Test, test, and test again. To avoid wasted material and frustration, we recommend you always test on a scrap piece to ensure you have the desired depth and alignment.
• Keep up with maintenance. Keep your tools clean, and your bits sharp, and be sure to complete the routine maintenance tasks regularly on your engraver. This will ensure you get the best and most accurate result for years to come.

So, why choose rotary engraving? Whether you’re creating for profit or creating something pretty, rotary engraving will give you professional, durable, and long-lasting results.

Rotary engraving is a powerful tool for creating detailed and durable designs on various materials. By understanding its process, applications, and advantages, you can unlock endless possibilities for customization and creativity. Ready to try rotary engraving? Explore our range of rotary engraving tools and machines to get started today!