Laser cutting stands out among precision cutting technologies because it is fast, precise, and leaves clean, smooth edges. Lasers can cut many metals and non-metallic materials in simple or complex shapes while using raw materials efficiently for low waste. As a result, it saves time and money for low- or high-volume production.
Continual advances in material handling, computer integration, and automation have expanded and improved laser cutting capabilities. It is widely used to make parts and products for applications, from medical devices to automotive components, and from industrial gaskets to protective packaging.
Here we’ll look at some of the advantages laser cutting offers different industries, along with innovations that are driving the future of this valuable process.
Precision and Accuracy
The laser’s movements are driven by a computer and CAD program, which controls the position and direction of cutting. As a result, the laser makes the same motions repeatedly, and variation between finished parts is minimal. Because lasers are non-contact, they leave a tiny heat-affected zone (HAZ), which limits the risk of damage, scorching, or warping where cuts were made, for accurate fit in assemblies.
Speed and Efficiency
Lasers follow a pre-programmed cutting path, so movements are quick and efficient. And while different types of lasers (e.g., CO2, Nd:YAG) can be used with different materials, fiber laser cutters travel quickly, even through materials like steel plating, making them a quick and powerful option. This increases throughput, which further reduces turnaround time and helps manufacturers meet tight deadlines, bring new products to market more quickly, and address demand. Laser cutters are also valuable in automated manufacturing processes because they can operate continuously with limited oversight.
Material Compatibility
Laser cutting is compatible with many metal and non-metal materials like steel, aluminum, titanium, polymers, glass, wood, and composites. Changeover from one type of material to another is quick, which is important for custom and small-batch production. And because lasers make clean, smooth cuts with no edge damage, component fit-up is not compromised, and secondary processes like sanding or grinding are not needed.
Reduced Waste and Cost-Effectiveness
Cutting layouts arrange the pieces to be cut on sheets of material with minimal wasted space. The laser beam is tightly focused, so the width of the cutting path, called kerf, is as narrow as possible, and pieces can be spaced closely together. The kerf is vaporized by the laser, leaving clean and smooth edges.
Enhanced Safety
Laser cutting is a non-contact process and is safer for personnel than cutting with blades. Assist gases, such as oxygen and nitrogen, are often used to smother and cool cut areas to reduce chemical exposure. Modern laser cutting stations also incorporate safety features like automated shut-down mechanisms, lock-out gates and switches, and enclosures that place distance between the equipment and workers and walkways.
Flexibility and Customization
Because cuts are programmed into a computer that controls the laser, this cutting technology is flexible and can be used to cut pieces that are large or small, simple or complex. Computer-aided design (CAD) software quickly generates a pattern and layout, and adjustments or changes to shapes can be implemented efficiently.
The Future of Laser Cutting Technology for Precision Components
Laser cutting technologies help manufacturers reach automation, productivity, and sustainability goals while enhancing part quality. Integrations with new technology are expanding its role in manufacturing.
3D Laser Cutting Integration with Additive Manufacturing
3D laser cutting makes it possible to trim, cut, and shape items in the X, Y, and Z axes as well as along rotational and diagonal lines. In conjunction with 3D printing, it is possible to remove material with a multi-axis laser for precision components.
Augmented Reality (AR) & Virtual Reality (VR)
Laser cutting technologies can be integrated with AR and VR systems for real-time monitoring, on-the-fly adjustments to cutting paths, modeling, and predictive maintenance.
Increased Automation Capability
Automated material handling, changeover, and conveyance technology shortens cycle times and speeds overall production. Robots can be used to transport materials, position them on the cutting bed, or remove completed cutouts, which saves on manual labor. Built-in sensors that detect out-of-alignment sheets, improper laser position or power level, or other maintenance needs make it easier to identify and fix problems before they impact an entire batch.
Laser Cutting at Rockford Specialties Co.
Laser cutting technology offers precision and efficiency to manufacturers in many industries. Rockford Specialties Co. provides experienced laser cutting for mild steel, stainless steel, and aluminum at speeds up to 800 inches per minute (IPM) and tolerances within +/- 0.005 in. Contact us to learn more about our capabilities or to get started on your next project.