Laser cutting has become an increasingly popular method for cutting materials such as metal, plastic, wood, and glass. A wide variety of industries, including the automotive and medical device sectors, use laser cutting because it offers a high degree of accuracy and precision. Each of these industries has different requirements and uses laser cutting in different ways. The automotive industry, for example, uses laser cutting to manufacture car parts and precision components. The medical device industry creates medical devices and implants with laser cutting.
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The following article will discuss the eight laser-cutting uses and their importance:
The automotive industry has embraced the advantages offered by laser cutting to produce a range of components. Tolerances in the automotive industry are extremely tight, and laser cutting is well-suited to meet them. Laser cutting’s flexibility and capability to create complex shapes and designs make it a popular technology for producing car parts. In the past, car parts were created with stamping and die-cutting methods. However, these methods are not as accurate, nor can they create complex shapes and designs like laser cutting. The automotive industry primarily uses fiber lasers for cutting sheet metal due to their speed, precision, and ability to handle reflective materials like aluminum and stainless steel. Materials that are laser cut in the automotive industry include, but are not limited to, car parts, components, die-castings, forgings, and stampings.
The medical device industry utilizes laser cutting to produce a variety of products, including pacemakers, stents, and catheters. The laser beam melts, vaporizes, or burns away the material, leaving a clean, precise cut. Laser cutting is often used to create products with intricate designs, such as those intended for use within the human body. The type of laser cutting used will depend on the material being cut and the desired final product. For example, some medical devices are made from stainless steel, which is typically cut using fiber or ultrafast lasers for improved precision and reduced heat-affected zones. Other materials, such as plastics, can be cut with a fiber laser.
The jewelry industry is one of the most ancient industries in the world, with a long and rich history. In recent years, however, it has undergone a major transformation, thanks to the advent of laser-cutting technology. While traditional methods of jewelry making relied on manual labor and simple tools, laser cutting has allowed for a much more precise and intricate level of design. As a result, jewelry made with laser cutting is often more intricate than its traditional counterpart. Laser cutting in the jewelry industry is typically used to create detailed patterns and designs in metal, as well as to cut gemstones. It can also be used to engrave text or images onto jewelry pieces. Jewelry products that are commonly made with laser cutting include rings, pendants, earrings, and bracelets. The use of laser cutting in the jewelry industry has revolutionized the way that jewelry is made and has allowed for a whole new level of creativity and design.
Ceramic manufacturing is the process of shaping and firing ceramic materials to create products. Ceramics can be made from clay, glass, metal, or synthetic materials. Laser cutting can be used in the ceramic manufacturing process to create precise shapes and designs in the material. This type of cutting is often used to create intricate patterns and decorative elements in products. Common examples of products made with laser cutting include tiles, pottery, and sculptures. In ceramic manufacturing, ultrafast lasers such as femtosecond lasers are often preferred for technical ceramics due to their precision and minimal thermal damage, though CO₂ lasers can be used for softer ceramics or decorative applications. This method offers high precision and supports the creation of complex designs. CO₂ laser cutting is also relatively fast, making it ideal for use in the ceramic manufacturing process.
When it comes to the silicon industry, laser cutting is a vital process. Silicon manufacturing refers to the production of silicon wafers—thin discs of semiconductor material that are used in the fabrication of various electronic devices. The silicon industry typically uses ultrafast or solid-state lasers (e.g., femtosecond or Nd:YAG lasers) for precision dicing and patterning of silicon wafers. It is used to create the small-scale features found on silicon wafers. There are a variety of different products that are produced in the silicon industry, including integrated circuits, solar cells, and semiconductor chips. CO₂ laser cutting is used to create intricate patterns on these products, which are then used in a variety of electronic devices.
Packaging refers to the process of enclosing products or items for protection and handling. Laser cutting is utilized in the packaging industry to create various packaging products, such as boxes, containers, and lids. Two main types of laser-cutting technology are used in this industry: fiber lasers and CO₂ lasers. CO₂ lasers are typically utilized to cut cardboard, paper, and thin plastics. Fiber lasers are more commonly used for cutting metals and are less typical in packaging; CO₂ lasers remain the standard for cutting paper, cardboard, and thin plastics.
Metalworking is the process of shaping and forming metal into desired shapes using various tools. Laser cutting is often employed in the metalworking industry to cut metal into desired shapes. Some common products that are produced are: beams, columns, pipes, tubing, and sheet metal. These products can be used in a variety of industries, such as construction, automotive, and aerospace.
The woodworking industry is a sector of the manufacturing industry that produces wood products. These products can be used for construction, furniture making, or other purposes. Laser-cutting technology is often utilized in this industry to create precise and intricate designs in wood. Some commonly produced items are: furniture, cabinets, and decorative items. The type of laser cutting used in the woodworking industry is typically a CO₂ laser. This type of laser uses a beam of infrared light to cut through wood. The CO₂ laser can create very complicated designs due to the high level of precision that it offers.
The importance of laser cutting lies in its highly accurate and consistent method of cutting a wide variety of materials, including but not limited to sheet metal. It is also an effective alternative to traditional etching for certain applications, particularly where precision and repeatability are required. Laser cutting has several advantages over other methods of sheet metal cutting, including:
For these reasons, laser cutting is now the preferred method of sheet metal cutting for many applications.
Below are the best laser-cutting machines available on the market today:
Laser cutting differs for different materials in that each material has different physical and chemical properties that require different laser settings and processes. For example, metals are generally good reflectors of light, so they require higher-power lasers and special cutting techniques. Plastics, on the other hand, can be cut with lower-power lasers, but the edges of the cut can be very jagged and require post-processing. Glass is a transparent material, so it can be more difficult to cut with a laser. Special techniques, such as using a lens to focus the laser beam, are required to cut glass cleanly.
There are several materials that can be laser cut, including metal, plastic, and glass. However, the materials that can be laser cut depend on the type of laser used. For example, some laser cutters can only cut certain materials, while others can cut a wide variety of materials. If a CO₂ laser cutter is used, a variety of materials can be cut, including wood, plastic, glass, and metal. A fiber laser cutter, on the other hand, can cut stainless steel, aluminum, and brass. If you are unsure about what type of laser cutter you have or what materials it can cut, consult the user manual or contact the manufacturer.
The materials that cannot be laser cut are: highly reflective materials, such as mirrors, thin materials that can easily warp or melt, and materials that are dangerous to cut, such as asbestos or explosives.
No, in general, it is easier to laser-cut plastic than metal. Plastics absorb CO₂ laser energy more efficiently and melt or vaporize at lower temperatures. Metals, especially reflective ones like aluminum or copper, require higher laser power and often specialized equipment, such as fiber lasers, to cut effectively.
This article presented the eight different laser cutting uses, explained what they are, and discussed the importance of each. To learn more about the uses of laser cutting, contact a Xometry representative.
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Laser cutting is a technique that utilizes high-power lasers to cut through various materials, including metal. It’s known for its high precision, speed, and versatility, and is a preferred method for numerous industries. This guide aims to provide a comprehensive look at laser cutting metals, focusing on its process, capabilities, applications, and various parameters.Metal Laser Cutting
Yes, metal can be cut with a laser. In fact, laser cutting is one of the most efficient methods for processing various types of metals. It’s capable of delivering precise cuts, complex shapes, and high-quality edges, making it an excellent choice for diverse industries.
Metal laser cutting involves a highly concentrated laser beam that’s directed onto the metal surface. The heat from the laser melts or vaporizes the metal, producing a clean, accurate cut. Here are the main stages of metal laser cutting:
There are two main types of laser cutters used for metal cutting: Fiber laser cutters and CO2 laser cutters. Each comes with its unique strengths and drawbacks.
Fiber lasers are known for producing narrower beams, thus providing about quadruple the effective power for the same laser output energy. They operate faster and with greater precision than their CO2 counterparts. Fiber laser cutting has lower operating costs due to electrical efficiency and solid-state construction, but they require more nitrogen shielding gas in the cutting process. They are suitable for high-precision cuts on thinner metal parts.
CO2 laser cutters deliver a wider cutter beam width and are capable of higher device power. They are better suited for lower-precision cuts on thicker parts. The initial cost of equipment (CAPEX) for CO2 lasers is lower than for fiber lasers, but operating costs (OPEX) are higher per length of cut.
A metal laser cutter is composed of several key components:
When cutting metal with a laser, several parameters must be carefully managed to achieve the desired results:
The typical laser cutting tolerances for metals are:
The thickness of metal that can be cut with a laser depends on the type of laser and its power. Generally, a laser can cut steel up to 1 inch (25.4mm) thick, stainless steel up to 0.75 inches (19.05mm), and aluminum up to 0.5 inches (12.7mm).
Different types of metals have unique properties that make them suitable for laser cutting. Here’s a brief rundown of each of these metals and their physical and chemical properties:
Mild steel, also known as carbon steel, is a popular choice for laser cutting. It’s affordable, durable, and offers excellent weldability. With carbon content up to 0.3%, it’s not as brittle as higher-carbon steels.
Stainless steel is a corrosion-resistant alloy that’s ideal for a wide range of laser cutting stainless steel applications. It offers good strength and excellent resistance to oxidation.
Aluminum is a lightweight, soft, and ductile metal with excellent corrosion resistance thus making aluminum laser cutting ideal for a range of industrial applications.
Brass is an alloy of copper and zinc. It’s easy to machine, has good corrosion resistance, and is excellent for decorative purposes.
Copper has excellent thermal and electrical conductivity. It is tough, ductile, and can be readily welded and soldered.
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Galvanized steel is steel that has been coated with a layer of zinc to improve its corrosion resistance.
Titanium is known for its strength, lightness, and corrosion resistance. It’s one of the most difficult metals to cut, but laser cutting can handle it efficiently.
Nickel alloys are resistant to corrosion and can maintain their structural integrity at high temperatures, making them ideal for use in harsh environments.
Silver is a soft, white, lustrous metal that possesses the highest electrical and thermal conductivity of all metals.
Gold is a dense, soft, shiny metal that’s the most malleable and ductile of all known metals.
Platinum is a dense, malleable, ductile, highly unreactive, precious metal with a silvery-white color.
Zinc is a bluish-white, lustrous, diamagnetic metal. It’s somewhat less dense than iron and has a hexagonal crystal structure.
Tin is a malleable, ductile, highly crystalline, silvery-white metal. Its main use is to prevent corrosion.
Lead is a heavy metal that is denser than most common materials. It’s soft and malleable, and has a relatively low melting point.
Inconel is a family of austenitic nickel-chromium-based superalloys. It’s resistant to oxidation and corrosion and performs well at high temperatures.
The best metal for laser cutting depends on the specific application and requirements. However, mild steel, stainless steel, and aluminum are among the most commonly used due to their excellent machinability and compatibility with laser cutting.
Here are some of the key advantages of using laser cutting to cut metals:
Laser cutting is used in a variety of industries. Here are a few examples:
When laser cutting metal, it’s important to take into consideration a few key factors:
Common mistakes to avoid include:
Laser cutting metals involves several steps:
Before beginning the laser cutting process, there are a few key preparations:
Laser cutting metal is a precise and versatile method of shaping sheets of metal, but the cost can vary greatly depending on the specific needs of a project. Several factors influence the price including the type of metal, its thickness, the complexity of the cut, and the type of laser cutter used.
On average, laser cutting services can range from $1 to $1.50 per minute of cutting time for materials with a thickness of 1-2 mm. Thus, the cost for a single cut could range from a few dollars for simple cuts to several hundred dollars for complex, precision cuts on thicker materials. It’s essential to remember that these costs can escalate quickly for larger projects or more complex cuts. However, when factoring in the precision and versatility that laser cutting offers, many find it to be a worthwhile investment.
Keep in mind, these are just the service costs. If you’re considering purchasing a laser cutter, the upfront costs can be much higher.
The cost of a laser cutter for metal can vary widely, depending on the type of laser, the power of the machine, and its capabilities. The price of a fiber laser that can cut steel ranges from $30,000 to $600,000, while the price of a CO2 laser with steel-cutting capabilities ranges from $10,000 to $200,000.
Entry-level metal laser cutters can start at around $10,000 to $20,000, but these may have limited power and cutting capabilities. These options are often suited for hobbyists or small businesses that don’t need to cut thick metals frequently.
For more industrial-grade metal laser cutters with higher power and precision, the prices can range from $30,000 to several hundred thousand dollars. These machines are built for heavy-duty use and can handle larger volumes of metal with greater thickness.
Lastly, large, high-powered industrial metal laser cutters used in heavy-duty applications can cost even more, going into the millions. These machines are typically used in large manufacturing or industrial settings where high volume and precision are paramount.
The speed of a laser cutter can vary greatly depending on a number of factors including the type of laser (CO2, fiber, etc.), the power of the laser, the type and thickness of the metal, and the complexity of the cut.
For thin sheet metals (up to 1-2mm), laser cutting speeds can range from 100 inches per minute (IPM) to IPM. Thicker materials (e.g., 6mm and above) might have cutting speeds in the range of 10 IPM to 200 IPM.
It’s crucial to note that the speed of the laser cutter affects the cutting efficiency, but it’s also important to balance speed with the required precision and edge quality. Higher cutting speeds might result in increased heat and potential for burrs or rough edges, while slower speeds can offer better control and smoother cuts.
Manufacturers often optimize cutting parameters to achieve the best balance between speed and cut quality for a specific material and thickness, with various assist gases (e.g., nitrogen, oxygen) being used to help achieve these optimal conditions.
There are many excellent laser cutting machines on the market, but choosing the right one depends on your specific needs. The ideal laser cutter for metal should have:
One highly-regarded brand in the laser cutting industry is Accurl, а Chinese press brake and laser cutter manufacturer, known for its metal laser cutters.
There are several alternative processes used for cutting metal, including:
Compared to these alternatives, laser cutting provides a balance of speed, precision, and versatility. While other methods may be better suited to specific tasks or materials, laser cutting offers a broad range of capabilities that make it a versatile tool in metal fabrication.
Laser cutting is a versatile, precise, and efficient method for cutting metal. While the initial cost of laser cutting machines can be high, the speed and precision they offer can lead to increased productivity and reduced costs over time. With a variety of machines on the market, there is likely a laser cutter to fit any need or budget.
In laser cutting, assist gases such as oxygen, nitrogen, and air are commonly used. Oxygen is often used to cut ferrous metals due to its reactivity with the metal, which helps to speed up the cutting process. Nitrogen and air are used when a high-quality, oxide-free edge is needed, as they do not react with the cut surface.
A 100W CO2 laser is typically not powerful enough to cut through metal, especially if the metal is thicker. These lasers are often used for engraving or cutting non-metal materials like wood, acrylic, or leather.
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