Cutting operations are crucial components of part fabrication in the manufacturing sector, with one of the primary techniques being sheet metal laser cutting. This method is highly effective for cutting metal, alloys, and non-metals. Metal sheet and tube laser cutters employ a thermal cutting process that utilizes beams of light (lasers) directed onto the workpiece to melt or vaporize materials until the desired shape is achieved. This technique stands out as one of the most efficient methods for sheet metal cutting. In this article, we will provide essential information about laser cutting with metal sheet and tube laser cutters to help you make informed decisions before using this technology. Let’s dive in!
What is Metal Sheet and Tube Laser Cutter?
Subtractive manufacturing processes are essential for modifying materials in part fabrication, and metal sheet and tube laser cutters represent one of the standard methods for cutting and removing components from a workpiece. This technique involves utilizing laser beams to cut out pieces of material with remarkable accuracy.
The laser cutting process operates on computer numerical control (CNC) technology, which is responsible for its exceptional precision. Before initiating the CNC cutting or laser cutting operation, the operator must input codes or programs that detail the designs or patterns into the computer, ensuring a seamless and accurate cutting process.
Metal Sheet and Tube Laser Cutting Process
Metal sheet and tube laser cutting involves utilizing laser beams to melt metals and alloys, resulting in smooth, sharp cuts. This cutting process consists of two operations that work in harmony.
The first operation involves the material absorbing the focused laser beam, which provides the energy necessary to create the cut. The second operation features the cutting nozzle, which is concentric with the laser, supplying the process gas required for cutting. This gas serves to protect the processing head from vapors and splashes while also aiding in the removal of excess material from the kerf.
There are essentially three methods for laser cutting metal sheets and tubes.
1. Laser Beam Fusion Cutting
The laser beam fusion cutting process uses an inert gas, mostly nitrogen. The low-reaction process gas continuously vaporizes the cutting gap of the material. As the molten material gets removed, inert gas prevents oxidation at the cutting edge without interfering with the process.
This laser cutting method is suitable for cutting flat, thin sheets of aluminum alloys and stainless steel that require high aesthetic appeal and fewer finishing operations.
2. Laser Beam Sublimation Cutting
As the name suggests, laser beam sublimation cutting evaporates the material. Instead of melting the material like other laser cutting processes, they are immediately changed from solid to gas – sublimation.
Like fusion cutting, laser beam sublimation cutting uses inert gases to blow the material’s vapor out of the kerf. So, there are no oxidants on the cutting edge. It is often used in cutting organic materials like wood, leather, textiles, etc.
3. Laser Beam Flame Cutting
Laser beam flame cutting uses a combustible gas – oxygen to thrust out the molten material. The laser heats the workpiece creating spontaneous combustion after melting the material. The oxygen gas provides more energy for the cutting process through oxidation – an exothermic reaction.
Flame cutting is ideal for cutting mild steel and fusible materials such as ceramics. This cutting process may cause burns on the cutting surface since the gas is an oxidant. Proper optimization of the process parameters will help prevent the formation of burrs.
Types of Lasers for Metal Sheet and Tube Cutting
When it comes to metal sheet and tube cutting, different types of lasers are employed, each with its own advantages and applications. Here are the main types of lasers used in this process:
CO2 Lasers
CO2 lasers are widely used for cutting metal sheets and tubes due to their high power and efficiency. They produce a continuous wave of infrared light, making them effective for cutting thick materials. CO2 lasers are suitable for a variety of metals and non-metals, but they are particularly known for their ability to cut through thicker sheets with excellent edge quality.
Fiber Lasers
Fiber lasers are gaining popularity in the metal cutting industry due to their ability to cut reflective materials, such as aluminum and copper, more efficiently than CO2 lasers. They produce a high-intensity laser beam by passing light through a fiber optic cable, resulting in a more focused and concentrated beam. This technology allows for faster cutting speeds and greater precision, making fiber lasers an excellent choice for sheet metal and tube applications.
NdLasers (Neodymium-Doped Yttrium Aluminum Garnet)
Ndlasers are solid-state lasers that are often used for specific applications, such as cutting thicker materials or when high precision is required. They emit a concentrated beam of light that can be focused to achieve fine details. Ndlasers are suitable for cutting various metals and are often used in industries where precision is critical, such as aerospace and medical device manufacturing.
Disk Lasers
Disk lasers are similar to fiber lasers but use a different method to generate the laser beam. They are known for their efficiency and ability to cut thicker materials at high speeds. Disk lasers offer excellent beam quality and can be an ideal choice for applications that require precision cutting of metal sheets and tubes.
Ultrafast Lasers
Ultrafast lasers, including picosecond and femtosecond lasers, are used for specialized applications that require extremely high precision and minimal heat-affected zones. These lasers deliver ultra-short pulses of energy, allowing for intricate cutting and engraving on a variety of materials, including metals. While not as commonly used for general cutting tasks, ultrafast lasers are ideal for applications in electronics and micromachining.
Each type of laser offers distinct advantages depending on the specific requirements of the cutting application, including material type, thickness, and desired edge quality.
7 Benefits of Sheet Metal Laser Cutting
Let’s examine the benefits of laser cutting sheet metal to the manufacturing sector.
1. High-Precision and Accuracy
Laser cutting is a suitable fit for sheet metal cutting because of its extreme precision. The machines are equipped with the ability to make intricate cuts at extreme precision and accuracy. Industrially, laser cutting is the go-to technique for cutting sheet metal with specific details requiring tight tolerances.
Some cutters can make precise cuts with an accuracy of up to 0.0005 inches. This is why it has remained a mainstay in most manufacturing companies. Since the lasers melt away the metal parts, the cutters produce little or no burring. Instead, it leaves a clean, smooth, and sharp edge.
2. Automated Process
Laser cutting runs by Computer Numerical Control (CNC) systems. Once the technical operator inputs the programs into the computer, the process runs independently. Therefore, it requires less human interference and overall labor. Also, there’s little or no margin for error with increased cutting efficiency.
3. Damage Prevention
There’s this misconception that laser cutting metal causes warping. However, that is untrue. The heat from laser cutting only affects minute portions of the material, not affecting tolerance.
Moreover, the laser cutting process is quick; the lasers heat and melt away the portions to be removed. So, the heat does not significantly affect the other parts of the material. In most cases, there is no distortion or warping of your materials.
4. Compatible With Most Materials
Another critical advantage of this subtractive manufacturing method is its ability to work with an extensive array of materials. It easily cuts through each material, whether it is copper, aluminum, stainless steel, or even titanium. After all, it involves using lasers at very high temperatures to melt the material.
5. Relatively Low Cost
Indeed, laser cutting machines are expensive. However, compared to other CNC machines, it is more cost-effective. Moreover, it’s a single machine for all – that is, a single laser cutting machine is ideal for all your cutting operations. You do not need any machine modification for different cutting operations.
In addition, it’s durable. The device makes no contact with the materials you are cutting, so there is little, or no friction nor surface wear out. Also, it does not have multiple parts, so there are fewer maintenance and servicing requirements. In general, there’s a reduced operational cost of using a laser cutter compared to other customary manufacturing tools.
6. High Versatility
Besides the compatibility of laser cutting with most materials, the process is highly versatile. Unlike other devices, you can employ a laser cutter for several cutting functions, from simple to complex cuts and those requiring tight tolerances and intricate designs. This feature makes it an excellent choice for most industries.
7. Low Energy Consumption
Indeed, laser cutters require power to heat and melt materials effectively during cutting. However, the cutting technique is more energy efficient than other cutting methods.
In addition, unlike other machines, it has fewer moving parts, which means fewer energy requirements. Also, the machine’s high speed means quick cutting, saving time and energy.
Disadvantages of Metal Sheet and Tube Laser Cutting
While metal sheet and tube laser cutting offers numerous advantages, there are several disadvantages to consider:
Need for Skilled Operators
Effectively operating a laser cutting machine requires a skilled technician who understands its features and can quickly identify and rectify any issues that arise. Improper setup can lead to damage to both the materials and the machine. Therefore, if you plan to run a laser cutting service, hiring a professional is essential.
Thickness Limitations
Although laser cutters are compatible with most materials, they have limitations when it comes to cutting thicker metals. In general, laser cutters can efficiently cut aluminum sheets up to a maximum thickness of 15mm and steel sheets up to 6mm. For thicker materials, alternative cutting methods may be more suitable.
Emission of Harmful Fumes and Gases
The laser cutting process generates heat to melt the materials, which results in the release of harmful fumes and gases. To mitigate health risks, it is crucial to operate laser cutting machines in well-ventilated areas.
High Initial Investment
The upfront cost of acquiring a high-quality laser cutter can be significant, often exceeding $2,000, which is nearly double the price of other cutting machines, such as water jet cutters. Anyone looking to operate a business using laser cutting technology should be prepared for this substantial initial investment.
Tips for Effective Metal Sheet and Tube Laser Cutting
Select the Appropriate Materials
Choosing the right material is crucial in any manufacturing process. The material selected for your component should align with the desired properties of the final product. In addition to metal sheets like aluminum and zinc, consider using plastics and other polymers based on your specific requirements. Common material properties manufacturers prioritize include flexibility, malleability, ductility, and rigidity.
Use Software That Generates Vector Files
Laser cutting machines require vector files for operation. To create your designs, utilize software such as Adobe Illustrator to vectorize them. Acceptable file formats include .ai, .step, .eps, and others that support vector graphics.
Account for Kerf
Kerf refers to the material that evaporates when the laser beam interacts with the workpiece. When designing your part, it’s essential to factor in the kerf to ensure accuracy in your final dimensions.
Avoid Small Details Relative to Metal Thickness
The thickness of the metal is a critical consideration in laser cutting. As a general rule, avoid designing details smaller than the thickness of the metal sheet, as thicker materials reduce the laser’s ability to penetrate effectively.
Maintain Minimum Spacing Between Cutting Lines
Proper spacing is vital for achieving optimal results in laser cutting. The minimum distance between cutting lines should be equal to the thickness of the material. For example, if you are cutting a 2 mm metal sheet, ensure that there is a spacing of at least 2 mm between the cutting lines.
Applications of Metal Sheet and Tube Laser Cutting Parts
1. Medical Equipment
Trolleys, beds, surgical equipment, orthopedic pins, rods, etc., all contain laser-cut metals. Though many surgical instruments are now 3D printed, laser cutting is the go-to technique for fabricating them.
2. Jewelry Production
Most jewelry designs contain intricate designs which laser cutters can easily map out. Often, jewelry pieces are designed from thin materials. Hence, laser cutting is a good fit for jewelry fabrication.
3. Interior Design
Laser-cut sheet metals are an excellent choice for room dividers which can help improve the overall outlook of a room and create more space. Leveraging the precision of laser cutting with the manufacturer’s creativity can give you that custom looks you want for your room.
4. Aerospace Industries
Because of the high dimensional accuracy, the aerospace industry is one of the most significant users of laser cutting technology. Most of the parts of airplanes, and other devices like metal detectors, trolleys, conveyors, etc., undergo some cutting operations during manufacture.
Should You Outsource or Invest in a Laser Cutting Machine for Your Sheet Metal Parts?
Laser cutting techniques play a crucial role in various manufacturing operations, providing a highly effective method for cutting a wide range of materials, particularly sheet metals.
For small-scale manufacturing operations, outsourcing your cutting needs is often the most economical choice. By hiring a service for your laser cutting requirements, you can reduce costs and allocate those savings to other critical areas of production. For your laser cutting and sheet metal fabrication needs, consider reaching out to Waken.
What Other Cutting Processes Can I Consider for My Project?
While laser cutting is a popular high-precision cutting method in industrial manufacturing, it’s not the only option available. If you’re considering alternatives to laser cutting for shaping your metal sheets, here are some excellent methods to explore for your manufacturing needs:
- EDM (Electrical Discharge Machining)
- Water Jet Cutting
- CNC Milling
- Punching
Popular Brands Of Metal Sheet and Tube Laser Machines
There are many tube laser cutting machine brands available on the market. Some of the top brands based on their reputation, product quality, and customer satisfaction are:
- Trumpf
- Bystronic
- Amada
- Mazak
- BLM GROUP
- Krrass
Choosing a tube laser cutting brand depends on many factors, such as the material, tube diameter, thickness, etc. Considering all factors before deciding on a machine and a metal fabricator is essential.
If you’re looking for a metal fabricator specializing in tube laser cutting, let us be your go-to. For more information about our services and to receive a quote, get in touch here.
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