Hi everyone.

I am in the process of gathering up parts to build a DIY laser (based on the open source 2.x Laser designed by Barton Dring) and it's a 40 watt Co2 machine. I am building mine slightly larger (from about 20x12 to 24x18 inches cutting area). Given my cabinet is going to be larger I can likely fit a larger tube.

The materials I would mostly be cutting is: Balsa up to 1/2 inch thick, Lite Ply up to 1/4 inch thick, Birch Aircraft ply 1/2 inch thick.

Will a 40 watt tube suffice (man, I hope so)? If not, then what would be adequate, 60 watt? I know the optics (mirrors and lens need to be upgraded) and Power Supply parts will change too.
Is there any downside to going larger beyond cost? Spot size? Kerf width?

Thanks

Bob T.