The search for the ideal material for Carey masks continues. I have now tried black paper, paper card, HIPS, ABS, aluminium, steel and perspex. The one that gives the best result is the 1.5mm mounting card, as in the picture below.
http://www.btinternet.com/~gfcarey/s...point5card.jpg
I recently tried 0.5mm acrylic (perspex), thinking that the thinness would give much better diffraction spikes. It was not too bad, but not as good as the card. Thin acrylic is transparent so needed spray painting matt black.
The 0.5mm acrylic was very thin and needed a 3mm thick acrylic support, as in this image.
http://www.btinternet.com/~gfcarey/s...nt5acrylic.jpg
I think the success of the card is the sharpness of the cuts and the lack of distortion caused by the heat of the laser.
The added advantage of card is it is cheap!