Introduction: Laser Cut Ear Guard

About: Hi. My name is Adelle and I work for Trotec Laser, Inc. In my spare time I enjoy sharing projects for people to use on their lasers.

As we continue the fight against COVID-19 in our communities, we strive to keep out healthcare workers and those on the front lines protected. Many of these workers are wearing face masks with ear loops that begin to pull on your ears and cause discomfort with prolonged use. This adjustable ear guard will protect your ears while still providing proper protection.


  • CO2 laser cutter (We used a Trotec Speedy 360 80W with a 2" lens)
  • TroLase 0.06" (1.6mm) thickness (available at link below)

Step 1: Processing TroLase

Position a 0.06" (1.6mm) piece of TroLase into the laser machine and cut the material using the file provided. Keep protective film on the material.

Laser Parameters for Cutting*

  • Power: 60.00
  • Speed (%): 1.20
  • ppi/Hz: 1000
  • Passes: 1
  • Air Assist: On
  • Z-Offset: None

*Use these settings as a guide but make sure you adjust your settings if you have a machine with a different wattage.

Step 2: Assembling

Once processing is completed, wipe any excess dust or debris from the surface of the material and remove it from the laser system. Peel off the protective film for the front and back of the material.