Abstract CO2 laser cutting process of phenolic resin boards has been assessed using a design of experiments (DOE) based methodology. The feasibility and quality of this process is analyzed and compared with the results from laser cutting of particleboard panels. The present work demonstrates that phenolic resin boards can be successfully cut by CO2 lasers using a laser power of 3 kW at a 3.5 m/min cutting speed. The potential toxicity of the condensed residues formed on the cut edges and the fumes generated during the cutting of the phenolic resin have been also analyzed. CO2 laser cutting of phenolic resin boards is a feasible process provided special protective measures, here commented, are implemented.