Causes of Sudden Stoppage During Engraving

I. Software and Connection Issues (Most Common)

1. Data Transmission Interruption (USB/Cable Issues)
Cause:
This is one of the most common causes. Poor-quality USB cables, loose connections, overly long cables, or interference can cause brief interruptions in data transmission, leading the machine to stop.

Troubleshooting:

Reconnect both ends of the USB cable (computer and engraver).

Try using a high-quality, shielded, and as short as possible USB cable.

Keep the USB cable away from power cords and motor cables to avoid interference.

If using a network connection, check for network stability.

2. Computer or Software Issues
Cause:
Insufficient computer performance, system freezing, unresponsive software, or conflicts with other programs.

Troubleshooting:

Restart the software and computer — this is often the simplest and most effective fix.

Check the computer’s power management settings: ensure the system is not in “Power Saver” mode to prevent USB ports or hard drives from sleeping.

Lower the data output speed: in your laser engraving software (e.g., LightBurn), look for the “Output Frequency (kHz)” or similar setting. If it’s too high (above 20 kHz), reduce it to improve stability.

Open Task Manager while running the job to check whether CPU or memory usage is maxed out.

3. File or Design Issues
Cause:
The design file is overly complex, contains too many small line segments or points, or the G-code file is corrupted.

Troubleshooting:

Optimize the design: use “Combine,” “Simplify Path,” or similar tools in vector software to reduce unnecessary nodes.

Check for stray points: zoom in on your design to locate and delete tiny, irrelevant points or lines that may cause empty movements.

Regenerate the G-code: save the file as a new version or re-export it from the software.

II. Electrical and Hardware Issues

1. Power Supply Problems
Cause:
Unstable power supply to the laser engraver or computer.

Troubleshooting:

Check that all power plugs are firmly inserted.

Confirm that the voltage selector switch on the engraver is set correctly (110V/220V).

Avoid sharing a power circuit with other high-power appliances (e.g., air conditioners) that can cause sudden voltage drops.

2. Overheat Protection
Cause:
The laser module, stepper motor driver, or mainboard overheats, triggering an automatic safety shutdown.

Troubleshooting:

Check whether all cooling fans (laser, mainboard, and motor drivers) are running properly.

Ensure good ventilation in the workspace and avoid high ambient temperatures.

3. Motor Stall or Step Loss
Cause:
If machine movement is obstructed or the load is too heavy, the motor cannot reach its commanded position, and the controller triggers an emergency stop.

Troubleshooting:

Check that guide rails and belts are properly tensioned—not too tight or too loose.

Clean rails of dust and debris and apply suitable lubrication.

Check for any foreign objects blocking the laser head or gantry movement.

Reduce the motor “acceleration” setting in the software to allow smoother start/stop motion.

4. Limit Switch False Trigger
Cause:
The machine accidentally triggers a limit switch during operation, which causes an emergency stop and reset.

Troubleshooting:

Check whether the limit switch lever is loose.

Inspect cables for damage that could cause short circuits or false signals.

Move the laser head manually—if you hear a “click” before reaching the end, the limit switch may be triggering too early.

III. Control Board and Firmware Issues

1. Control Board Malfunction
Cause:
The components on the control board may be aged, damaged, or affected by static electricity.

Troubleshooting:

Observe the indicator lights on the control board when the machine stops—abnormal blinking or power loss may indicate a fault.

Restart the control board by turning the machine off and back on.

If possible, try refreshing or updating the firmware.