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In the current market, the field of cutting and machining is developing extremely rapidly. That also marks a turning point in the precision mechanical processing industry. In particular, laser cutting is gradually replacing traditional technologies with many outstanding features and advantages.
What is Laser Cutting technology?
Laser is the most advanced technology today, using laser beams to cut and engrave materials with many different energy sources to transform workpieces on all metals such as processing stainless steel, iron, steel, copper, aluminum, etc.
Some of the main technologies of laser cutting machines are optical, mechanical and electrical integration technology. Laser cutting technology has been widely used in automobiles, machinery, electric power, hardware and electrical equipment.
Compared with traditional plasma and oxyacetylene cutting processes, laser cutting technology has the advantages of fast cutting speed, narrow cutting lines, small heat-affected zones, good perpendicular cutting lines and smooth cutting edges.
What is CNC Laser Cutting?
CNC (Computer Numerical Control) laser cutting is a laser cutting technology that uses a high-powered laser beam guided by computer instructions to cut or engrave materials. This technique provides high precision and accuracy, capable of creating complex shapes and designs that are virtually impossible to achieve by hand. It is commonly used in industries such as automotive, aerospace, electronics, medical, and construction.
Materials and thickness used in laser cutting technology
The choice of material and its thickness are the main factors that determine the power and cutting speed requirements of the laser. Lasers can accurately cut a wide range of materials, including:
- Metals (e.g. steel, aluminum, brass)
- Plastics (e.g. acrylic, ABS, polycarbonate)
- Wood
- Glass
- Fabrics
The thickness of these materials can vary, typically from less than a millimeter to 20 mm for metals and even thicker for softer materials such as wood and plastics. Thicker materials typically require more laser power or slower cutting speeds to achieve the desired quality.
How does the CNC laser cutting process work?
Here is an overview of the CNC laser cutting process:
- CAD/CAM design and programming
The process begins with designing the desired shape or pattern using computer-aided design (CAD) software. Once the design is complete, it is converted into machine-readable code using computer-aided manufacturing (CAM) software. This code contains instructions that will guide the CNC machine through the cutting process.
- Material Preparation
The material to be cut, such as sheet metal, wood, acrylic, or other materials, is prepared and placed on the CNC laser cutting machine's work surface.
- Machine Setup
The CNC machine is set up for the specific material and thickness to be cut. This includes adjusting the laser's focus, selecting the appropriate cutting parameters (e.g., power, speed, and gas pressure for the assist gas), and ensuring the material is properly aligned.
- Laser Cutting
Once setup is complete, the CNC machine begins the cutting process. A focused laser beam is directed at the surface of the material, heating it rapidly to the point of melting or vaporizing it. The high-energy laser beam cuts through the material along a programmed path, guided by CNC instructions.
- Material Removal
As the laser beam travels along the programmed path, it melts or vaporizes the material. The molten or vaporized material is pushed away from the cut line (cut line), leaving the desired shape or pattern.
- Cooling and Solidification
As the laser cuts through the material, it generates a significant amount of heat. Cooling mechanisms, such as water jets or gas, are often used to prevent the material from overheating and aid in solidification.
- Quality Inspection
After the cutting process is complete, the cut parts are inspected for accuracy and quality. Any defects or deviations from the intended design are assessed and adjustments can be made if necessary.
- Post-Processing (Optional)
Depending on the application, the cut parts may undergo additional post-processing steps, such as deburring, surface treatment, or assembly.
4 Main factors affecting the precision of Laser Cutting process
In the laser cutting machine, the parameters of the laser beam, the efficiency and precision of the machine and system directly affect the efficiency and quality of laser cutting. Cutting precision is the first factor to evaluate the quality of the laser cutting machine.
The factors affecting the cutting quality of the laser cutting machine include cutting speed, focusing position, auxiliary gas, laser output power and workpiece characteristics, which are analyzed in detail below.
1 - Laser output power
The laser cutting machine generates energy from the continuous wave laser beam output. The choice of laser power and mode will have an impact on the cutting quality. In actual operation, it is often adjusted to a higher power to meet the cutting of thicker materials. At this time, the beam mode (the distribution of beam energy on the cross section) is more important.
Under the condition of high power, the focus obtains higher power density and better cutting quality. The modes are not consistent throughout the effective operation of the laser beam. The condition of the optical elements, the slight change of the laser working gas mixture and the fluctuation of the flow will affect the mode mechanism.
2 - Adjusting the focus position
The relative position between the focus and the workpiece surface is especially important to ensure the cutting quality. In most cases, when cutting, the focus position is just above the workpiece surface or slightly below the surface.
In the whole cutting process, ensuring a constant relative position between the focus and the workpiece is an important condition to obtain stable cutting quality. When the focus is in a better position, a smaller gap, higher efficiency and better cutting speed can be obtained.
In most applications, the beam focus is adjusted just below the nozzle. The distance between the nozzle and the workpiece surface is generally about 1.5mm. After the laser beam is converged, the spot size is proportional to the focal length of the lens.
After the beam is focused by the short focal lens, the spot size is very small and the energy density at the focal point is very high, which is very beneficial to cutting materials;
The disadvantage is that the focal depth is very short and the adjustability is small. It is more suitable for high-speed cutting of thin materials. The long focal lens has a wide focal depth and sufficient energy density, which is more suitable for cutting thick workpieces.
3 - Cutting speed
The cutting speed of the material is proportional to the laser energy density, that is, increasing the energy density can improve the cutting speed. The cutting speed is inversely proportional to the density (specific gravity) and thickness of the material being cut. When other parameters remain unchanged, the factors to improve the cutting speed are: increase the power (within a certain range, such as 500 ~ 2000 W);
- Improve the beam mode (for example, from high-order mode to low-order mode to TEM00);
- Reduce the focus spot size (for example, focus with a short focal length lens);
- Cut materials with low initial evaporation energy (such as plastic, mica plate, etc.);
- Cut materials with low density (such as white pine, etc.); Cut thin materials.
4 - Auxiliary gas pressure
Auxiliary gas is necessary for cutting materials with a laser cutting machine, and gas pressure is a very important factor. The auxiliary gas is ejected coaxially with the laser beam to protect the lens from contamination and blow away the slag at the bottom of the cutting area. For non-metallic and some metallic materials, use compressed air or inert gases to process the molten and vaporized material, while inhibiting excessive burning in the cutting area.
Laser Cutting technology advantages
Here is an in-depth exploration of the various benefits that laser cutting offers that set it apart in the metal fabrication industry and beyond.
- Accuracy
The appeal of laser cutting is its pinpoint accuracy. Unlike other cutting methods, lasers offer high precision, ensuring that parts and products adhere to tight tolerances. This precision is especially beneficial in industries where even a small deviation can lead to serious quality issues. Compared to plasma cutting or waterjet cutting, the laser cutting process stands out for its meticulous attention to detail.
Benefits of precision Laser Cutting:
- Better adherence to design specifications.
- Reduced waste due to errors.
- Improved product quality leads to customer satisfaction.
- Less rework, resulting in a more streamlined manufacturing process.
- Material handling versatility
Whether you are processing metals like stainless steel, aluminum, or titanium, or working with non-metals like wood, plastic, and paper, laser cutters demonstrate an admirable ability to handle a wide range of materials.
Materials commonly handled by Laser Cutters:
- Metals: Stainless steel, aluminum, titanium, copper, etc.
- Non-metals: Acrylic sheets, wood, plastic, paper, and even some fabrics.
- Reflective materials: While some cutting processes struggle with these issues, laser cutters can handle them efficiently.
- Increased speed and efficiency
In a manufacturing industry driven by speed of delivery and throughput, laser cutting offers manufacturers a significant advantage. In addition to the actual cutting speed, the advantages come from reduced setup times, reduced tool changeover times and the complete absence of physical tools. All of these efficiencies mean that products can reach the market in record time, which is a significant benefit for businesses that need to meet tight delivery schedules.
Efficiencies achieved through Laser Cutting:
- Minimal material waste, resulting in cost savings.
- Streamlined operations with computer-controlled precision.
- Higher productivity with faster setups and less downtime.
- Cost effectiveness
In addition to the direct savings from reduced waste, the energy consumption of laser cutting machines, especially when compared to some traditional methods, is significantly lower. Additionally, due to the need for less extensive repairs and maintenance, the long-term costs associated with these machines are more predictable.
Cost benefits of Laser Cutting:
- Lower energy bills due to efficient energy consumption.
- Less rework, resulting in cost savings.
- Reduced maintenance costs, especially when compared to older cutting processes.
- Higher product yields due to minimal waste.
- Flexibility in design and detailing
Engineers, artists and manufacturers have at their disposal a tool that can turn the most complex designs, patterns and ideas into reality. The advantages of laser cutting in this area are unparalleled, as even the most delicate and intricate patterns can be achieved with pinpoint accuracy. The combination of computer programs and the capabilities of the laser beam means that levels of detail that were previously thought impossible can be achieved
Design advantages with Laser Cutting:
- The ability to handle both large and small scale projects with the same precision.
- The ability to handle complex patterns and designs without compromising on quality.
- Reduced need for post-cut finishing due to clean and precise cuts.
- Non-contact processing
As the laser beam does not touch the material it is cutting, wear and tear on the machine is significantly reduced. This not only extends the life of the cutting tool but also reduces the possibility of material damage, ensuring increased precision in the finished product.
- Less material damage: Unlike traditional cutting methods such as plasma cutting, the lack of physical contact in the laser cutting process means that the material is hardly disturbed.
- Extended tool life: The machinery involved is subjected to reduced stress, resulting in reduced maintenance and repair needs.
- Reduced need for finishing
Laser cutting has become synonymous with their sharp edges and the highest level of finish. Such meticulous results mean that parts often move on to the next stage of production without the need for extensive post-processing, which is a boon for manufacturing companies looking to save time and money.
- Superior edges: Laser cutters deliver smooth edges, reducing the need for further refinement.
- Cost and time efficiency: The reduced need for post-cut processing can result in significant savings in both time and money.
- Reliability and consistency
The manufacturing industry often values consistency, a criterion where laser cutters shine. Their inherent ability to repeat the same cut over and over again not only ensures product quality, but also ensures manufacturers consistent results throughout the production process.
- Predictable Results: Laser cutting delivers consistent output, even over long periods of time.
- Improved Product Quality: Consistent cuts produce uniform products that meet stringent industry standards.
- Automation and customization
The combination of laser technology and computer programs has ushered in a new era of manufacturing. Tailored cutting processes specific to each project have become possible, providing manufacturers with both increased efficiency and improved product quality.
- Design Flexibility: With computer-aided design, laser cutting services can produce a wide variety of shapes and patterns.
- Reduced Human Intervention: The automation aspect minimizes manual handling, streamlining the entire process.
- Operational safety
Laser cutting, when compared to other laser cutting methods, is safer. The compact nature of laser cutting setups helps to limit potential hazards, creating a safer work environment.
- Enclosed setups: Many laser cutters operate in enclosed systems, minimizing risk.
- Minimized physical risks: With no need for manual tool changes, operators are exposed to fewer physical risks.
- Reduced power consumption and energy efficiency
Coming out of an era dominated by energy concerns, laser cutting has a clear foothold. When compared to cutting technologies such as plasma cutting and waterjet cutting, lasers are significantly more energy efficient. This association with green initiatives is increasingly becoming a magnet for modern businesses.
- Reduced energy bills: Using a laser cutter can significantly reduce energy costs.
- Environmentally friendly: By consuming less energy, laser cutting indirectly supports environmental sustainability efforts.
Disadvantages of Laser Cutting
Laser cutting is a precise and efficient process that is widely used in manufacturing. But like any technology, it has its limitations, and understanding these limitations is essential for those working in the metal fabrication and manufacturing industries.
- Some Evaporation Products
For example, when machining specific materials such as plastics, the extremely high temperatures from the laser cutter can cause these materials to evaporate rather than cut cleanly. This is a particular concern for manufacturers, especially when precision is critical. It is important to note that:
- Making specific equipment adjustments can mitigate this issue.
- However, these changes to the laser cutter often come at a significant cost, making it a less attractive solution for some.
- Highly skilled personnel are needed
Unlocking the full potential of laser cutting machines is not easy, expertise is very important. Laser cutting services often emphasize the importance of skilled professionals. Without these machine operators, identifying problems and ensuring the accuracy and quality of the cut can become difficult. With such a shortage of skilled professionals in the market, hiring is not only a need but also a costly issue.
- Hazardous gases and fumes
Safety is paramount in the manufacturing industry. With laser cutting, especially when working on materials such as plastics, toxic fumes and fumes are emitted. These pose health risks and need to be dealt with effectively: Manufacturers need to invest in ventilation and exhaust systems. Appropriate safety procedures must be in place to protect workers from inhaling these toxic gases.
- Material thickness limitations
Laser cutting offers great flexibility but is not without its limitations:
- The process has limitations on the thickness of material it can effectively cut.
- While laser cutters boast flexibility, when it comes to extremely thick materials, other cutting methods such as plasma cutting or even waterjet cutting may be a more efficient option.
- For projects involving thicker sheets or materials that exceed a specific range, manufacturing companies may need to use alternatives to laser cutting.
- Upfront costs
The initial investment associated with laser cutting technology can be significant. For businesses, especially small businesses, this is an important factor to consider:
- The machinery that harnesses laser technology is an expensive asset in itself.
- Installation costs are often overlooked, adding to the initial cost.
- Training is essential. To operate these machines efficiently and safely, companies need to invest in training their employees, which adds to the overall cost.
How much does laser cutting cost?
Laser cutting is obviously more cost-effective, but how much depends on the amount of material being cut and the time it takes to complete the job. As with any type of fabrication process, the cost of laser cutting steel per square inch can vary based on many factors
- Factors that affect the cost of laser cutting:
Understanding each factor can lead to more effective budgeting and cost reduction.
1 - Material Cost
- Material Types: Different materials have different costs, with metals typically being more expensive than plastics.
- Material Thickness: Thicker materials typically result in increased costs due to the need for higher laser power and slower cutting speeds.
2 - Machine operating costs
- Machine Power: Higher powered lasers can cost more to operate due to increased energy consumption.
- Maintenance Regular maintenance is required to keep the laser cutter in optimal condition, which adds to the cost.
3 - Labor costs
- Setup Time: The time required to set up the machine for specific jobs contributes to increased labor costs.
- Operator Skills: Highly skilled operators can increase efficiency but may command higher wages.
4 - Design complexity
- Intricate Cutting: More complex designs require more time and precision, increasing costs.
- Documentation Preparation: The need to perform significant design work before cutting can also affect overall costs.
5 - Production Volume
- Single Orders vs. Bulk Orders: Larger order quantities can reduce per-unit costs due to economies of scale.
- Recurring Orders: Regular, repeat orders can result in lower costs as setup and design become more streamlined over time.
- Calculating laser cutting costs
When evaluating laser cutting costs, it is essential to understand both the cost per unit and the software tools available for accurate estimates.
Calculating cost per unit:
To calculate the cost per unit of laser cutting, one must consider several factors:
- Material Type: Harder materials can increase wear on cutting equipment.
- Material Thickness: Thicker materials require more energy and time to cut.
- Complexity: Complex designs require slower speeds and more detailed work, which increases costs.
- Cutting speed: Faster cutting speeds can reduce costs but can impact quality.
- Quantity: Higher volumes typically reduce costs per unit due to economies of scale.
A typical cost per unit formula would look like this:
Cost per unit = (Material cost + Labor cost + Overhead cost + Profit margin) / Number of units
- How to reduce laser cutting costs
Cost efficiency can be achieved with laser cutting using a combination of thoughtful design, appropriate material selection, and streamlined manufacturing processes. These targeted strategies are essential in minimizing costs without compromising quality.
1 - Optimize design
Efficient design plays a key role in reducing costs. Simple layouts with fewer cuts can result in less machine time and therefore lower costs. Designers can reduce the cost of a product by analyzing design elements such as cut lines and nested patterns, ensuring that materials are used efficiently. By implementing software solutions that improve design efficiency, one can reduce the need for costly proprietary programs.
2 - Material selection
The selection of the right material can significantly impact the overall cost. It is beneficial to consider the use of recycled materials which can provide a cost advantage. Material costs vary widely, so choosing the right type at the optimal price is essential. A thorough evaluation of the material properties in relation to their suitability for the project allows one to balance cost with performance.
3 - Efficient manufacturing practices
Using efficient manufacturing practices helps reduce the cost of laser cutting. Manufacturers can save more money by optimizing machine setup, taking advantage of economies of scale with larger volume orders, and managing operating hours. Strategies such as minimizing downtime and properly maintaining equipment will ensure that the cost per unit is kept as low as possible. Memberships with suppliers can reduce costs by cutting costs, which translates into savings over time.
How long does a CNC laser cutting job typically take?
The duration of a CNC laser cutting operation varies greatly and depends on a number of factors. These factors can include the power of the laser, the complexity of the design, the thickness and type of material, and the required precision.
For a rough guide:
- For thin sheet metal (1mm), a CNC laser cutter can take just a few minutes to cut a simple shape, but complex patterns can take up to 15-20 minutes.
- For thicker material (10mm), cutting times can range from 20 minutes for simple designs to over an hour for more complex patterns.
- If engraving is involved, the turnaround time can be even longer, depending on the complexity and size of the engraving.
Remember that this is just a rough estimate and the actual cutting time may be shorter or longer, depending on the factors mentioned above.
Common types of CNC Laser cutters
There are different types of CNC laser cutters, distinguished by the type of laser they use and the number of axes they operate on. Here’s a closer look at these types:
- Carbon Dioxide (CO₂)
CO2 laser cutters are some of the most popular and versatile types of laser cutters. They use a gas mixture with a high concentration of carbon dioxide, electrically excited to create a powerful laser beam. These machines are well suited for cutting, engraving, and drilling a wide range of materials, including most metals and non-metals.
- Fiber Laser Cutting
Fiber laser cutters use a solid-state laser with an optical fiber infused with rare earth elements as the laser medium. Fiber laser cutting is known for its efficiency, precision, and excellent beam quality. Fiber lasers are particularly effective for cutting metals and are commonly used in industrial applications.
- Neodymium-doped Yttrium Aluminum Garnet (Nd:YAG or YAG)
YAG laser cutters use a crystal as the laser medium, doped with neodymium (Nd). These lasers are effective for engraving and cutting metals and ceramics, and can also be used for welding. YAG lasers can produce high-power beams and can operate in both pulsed and continuous modes.
- Based on Axis
A CNC machine's axis refers to the number of directions in which the cutting tool can move. More axes allow for more complex shapes and finer cuts.
+ 2-Axis CNC Laser Cutting:
A 2-axis CNC laser cutter operates on a 2D plane. This machine can move the laser head horizontally (X-axis) and vertically (Y-axis), which is optimal for cutting flat sheet materials such as metal and wood.
+ 3-Axis CNC Laser Cutting:
In addition to the capabilities of a 2-axis machine, a 3-axis CNC laser cutter can move the laser head up and down (Z-axis), providing greater cutting depth. This is especially useful for engraving applications.
+ 4 Axis CNC Laser Cutting:
A 4 axis CNC laser cutter can perform all the movements of a 3 axis machine, but can also rotate the workpiece around an axis, usually the X or Y axis. This additional rotation allows for the creation of complex shapes and geometries.
+ 5 Axis CNC Laser Cutting:
A 5 axis CNC laser cutter offers even more versatility, with the ability to rotate the workpiece around two separate axes at the same time. This provides great control and precision in creating complex, multi-dimensional shapes.
+ 6 Axis CNC Laser Cutting:
A 6 axis CNC laser cutter is the most advanced type, having all the capabilities of a 5 axis machine plus an additional axis of rotation. This allows the machine to cut from virtually any angle, creating extremely complex and precise cuts.
Some common applications of laser cutting technology
Computer Numerical Control (CNC) laser cutting technology is used in many different industries due to its precision and ability to shape a variety of materials.
Here are some areas where this technology is frequently used:
- Automotive industry:
CNC laser cutting plays an important role in vehicle manufacturing, used to precisely shape sheet metal parts, cut body panels, and create small components with complex designs.
- Aerospace industry:
In the aerospace industry, precision is paramount. CNC laser cutting machines are used to produce precision parts with tight tolerances, taking full advantage of the ability to cut metals and exotic composite materials used in the industry.
- Electronics industry:
From engraving circuit boards to manufacturing smartphone components, CNC laser cutting machines are versatile tools in electronics manufacturing.
- Medical Device Manufacturing:
CNC laser cutting machines support the production of surgical instruments, medical devices, and orthopedic implants, where detail and precision are of utmost importance.
- Jewelry Industry:
To create complex designs with high precision, CNC laser cutting technology is widely used in jewelry making for cutting and engraving purposes.
- Construction Industry:
Large-scale CNC laser cutting machines support the cutting of structural components for buildings, bridges, and other construction projects.
Precise laser cutting service on demand at Intech
Intech Company is one of the leading units in the field of laser cutting processing in Vietnam. With a modern machinery system, a team of experienced technicians and a professional production process, Intech is committed to bringing customers high-quality laser cutting products, meeting all requirements for precision and aesthetics.
Why should you choose laser cutting service at Intech?
- Products are manufactured on a modern technological line, ensuring quality and precision.
- Intech always offers reasonable prices, suitable for each order.
- Intech always ensures on-time delivery according to customer requirements.
- Intech's staff is always ready to advise and support customers.
If you are in need of laser cutting services, please contact Intech immediately for the best advice and quote!
Contact information:
- Hotline: 0966 966 205
- Email: sales.cokhiintech@intech-group.vn
- Address: Lot 6, Lai Xa Industrial Park, Tay Tuu Ward, Hanoi City
