T-Bolt connection using laser-cut 1/4″ panels

Laser cutting is a great technique for quick fabrication, in part because of the very small point size of the laser beam. The minuscule kerf of a laser cut allows for very tight 90° angles on interior (and exterior cuts). This makes it easy to laser-cut thin panels of material for joining, as oomout demonstrates in this post on instructables.com (example pictured below). One of the drawbacks of laser cutting is the limited depth of materials that can be successfully through-cut; the laser cutter that I have access to can get through about 1/2″ of MDF or plywood, but the cuts are very charred and not perpendicular due to the hourglass shape of the laser’s focal point.