This article contains comprehensive information about laser cutting and laser drilling. Read further to learn more about:
Laser cutting is an advanced method of slicing materials by utilizing a highly concentrated, coherent beam of light. This technique is effective for cutting through metals, paper, wood, and acrylics. As a subtractive manufacturing process, it works by removing material through mechanisms like vaporization, melting, chemical ablation, or controlled crack propagation. By employing laser optics powered by Computer Numerical Control (CNC), the technology can create holes as small as 5 microns (”). One of the standout advantages of this process is the lack of residual stresses on the workpiece, making it suitable for both delicate and brittle materials.
Various techniques are employed in laser drilling, including single-shot, percussion, trepanning, and helical methods. While single-shot and percussion drilling excel in rapid hole production, trepanning and helical techniques are renowned for their precision and the superior quality of holes they generate.
Characterized as a non-contact method, laser cutting allows for slicing without direct physical interaction with the material. This process is especially effective for crafting high-strength or brittle items, such as diamond tools and refractory ceramics. First introduced in 1965, laser cutting initially served for drilling diamond dies and later expanded to cutting robust alloys and metals, like titanium, particularly in aerospace. Today, the versatility of laser cutting is evident as it is widely applied to a diverse range of materials, including polymers, semiconductors, gems, and metallic alloys.
Laser stands for "light amplification by stimulated emission of radiation." In modern manufacturing, laser technology plays a pivotal role in precision cutting, metal fabrication, and rapid prototyping. In addition to metal cutting, lasers are employed for wide-ranging industrial applicationsâincluding joining, heat treating, quality control inspection, engraving, and freeform manufacturing. Unlike other laser machining processes, laser cutting demands higher power densities but involves shorter interaction times, resulting in clean, accurate cuts for materials like stainless steel, aluminum, plastics, and composites.
Lasers are produced by a high-intensity light source inside a reflective cavity, which houses a laser rod responsible for generating radiation. The light source stimulates the atoms in the laser rod, causing them to absorb specific wavelengths of light. Light is made up of photons, which energize the atoms in the laser rod. These energized atoms then emit two additional photonsâeach matching the wavelength, direction, and phase of the original photonâin a process known as stimulated emission. This creates a cascade of photon production as new photons stimulate further energized atoms, resulting in a highly concentrated, coherent light source ideal for precision laser cutting applications.
The photons travel between parallel mirrors located at either end of the laser rod, remaining confined within the rod. One mirror is partially transmissive, allowing some of the light to escape the cavity. This escaping stream of coherent, monochromatic light forms the laser beam used for cutting various materials. Additional mirrors or fiber optics direct this light into a focusing lens, which narrows the beam to a fine point for high-precision material processing. This focused energy provides the power and accuracy necessary for clean cuts, micro-machining, and high-speed industrial manufacturing.
The three main types of lasers used in industrial laser cutting services are CO₂ lasers, Nd-YAG (Neodymium Yttrium-Aluminum-Garnet) lasers, and fiber-optic lasers. Each laser type utilizes unique lasing media and operational principles to achieve optimal performance across a wide range of materials and thicknesses.
Fiber-optic lasers are the latest and most popular laser types due to their ability to generate multiple wavelengths for greater versatility and precision. These fiber lasers utilize an optical fiber cable made of silica glass doped with rare earth elements to guide and amplify the light beam. The result is a laser beam that is both straighter and smaller in diameter, offering exceptional accuracy for detailed metal cutting, etching, and high-speed automated manufacturing.
Fiber lasers vary according to their laser source mixture, including ytterbium-doped, thulium-doped, and erbium-doped compositions. The selection of doping element is based on application requirements, as each produces a unique wavelength range ideal for specific materialsâsuch as copper, brass, aluminum, and other metals. For example, erbium generates light in the 1528 nm to 1620 nm range, ideal for telecommunications, while ytterbium produces industrial laser light at wavelengths of 1030 nm, 1064 nm, and 1080 nm, frequently used in sheet metal and heavy manufacturing.
Fiber-optic lasers are available in two primary modes: single-mode and multi-mode. Single-mode lasers have a core diameter from 8 ”m to 9 ”m, producing a tightly focused beam with superior energy densityâideal for micro-machining, electronics manufacturing, and medical device fabrication. Multi-mode lasers feature core diameters between 50 ”m and 100 ”m, delivering higher total power for thicker or less precise cuts. Among these, single-mode fiber lasers are more efficient, producing a higher quality beam and enabling highly intricate designs.
Classified as solid-state lasers, fiber-optic lasers utilize a silica glass core doped with rare earth elements as their power source, setting them apart from gas lasers like CO₂ lasers, which utilize a gas medium. This innovation enables fiber laser systems to deliver wavelengths from 780 nm to 2200 nm, providing remarkable flexibility for cutting thin sheets, engraving, and marking. In contrast, CO₂ lasers typically operate in the 9600 nm to 10,600 nm wavelength range and excel at cutting organic materials like wood, acrylic, and certain plastics. This functional diversity makes fiber-optic lasers a top choice for sheet metal processing, automotive manufacturing, and electronics assembly.
CO₂ lasers remain a cornerstone of laser cutting technology for both general manufacturing and industrial fabrication. These gas lasers use a discharge lasing medium composed of 10â20% carbon dioxide, 10â20% nitrogen, and trace amounts of hydrogen, xenon, and helium. CO₂ lasers differentiate themselves from solid-state lasers by relying on electrical dischargeârather than light pumpingâto energize the gas molecules. When an electrical current passes through the lasing medium, nitrogen molecules are excited and transfer their vibrational energy to CO₂ molecules, bringing them to a metastable state. The excited CO₂ molecules then emit powerful infrared light at wavelengths of 10.6 ”m or 9.6 ”m, ideal for deep material penetration and high-speed industrial cutting.
The resonating mirror system reflects and amplifies these photons, with one mirror designed to allow the exit of the concentrated infrared laser beam, which is then focused for cutting, engraving, or etching. After their energy is released, CO₂ molecules are returned to ground state by transferring residual energy to the helium atoms, which are then cooled by advanced laser cooling systems. CO₂ lasers boast an efficiency of around 30%, higher than many alternative laser types, and are widely used for processing organic materials, thick non-metals, and in large-format laser cutting machines.
Crystal-based lasers, such as ruby and Nd-YAG lasers, belong to the family of solid-state lasers and offer unique advantages in precision cutting and micro-fabrication. Nd-YAG lasers are particularly valued for their capability to produce high-powered bursts of energy, making them indispensable in welding, drilling, medical surgeries, and precision manufacturing. The Nd-YAG laser utilizes a synthetic YAG (YâAlâ Oââ) crystal doped with 1% ionized neodymium (NdÂłâș), where Nd ions substitute for Y ions. The laser rod measures about 4 inches (10 cm) in length and 2.4 to 3.5 inches (6 to 9 cm) in diameter. Both ends are polished and coated for maximum reflectivity, serving as the resonator system required for efficient photon amplification.
Pumping in Nd-YAG lasers is commonly achieved with krypton flashlamps or laser diodes, which excite the Nd ions to high energy states. These ions then transition to a metastable state before releasing energy as concentrated infrared light (wavelength 1064 nm) during their return to ground state. This process makes Nd-YAG lasers suitable for detailed machining, deep engraving, and even micro-welding of metals and non-metallic substrates.
Light traveling through a fiber-optic cable remains exceptionally contained, minimizing energy loss and enabling consistent power delivery. This robust energy transmission enhances cutting stability and productivity, reducing maintenance and increasing uptime in advanced sheet metal laser cutting operations. Fiber-optic laser systems typically require less alignment and maintenance compared to traditional CO₂ or crystal laser machines, making them an excellent choice for automated, high-throughput manufacturing environments.
Furthermore, with their flexibility and energy efficiency, fiber-optic laser cutters are rapidly becoming the preferred option for precision job shops and manufacturers seeking lower operating costs, faster turnaround, and the capacity to process reflective and sensitive materials without surface damage.
Laser cutting utilizes assist gasesâsuch as compressed air, nitrogen, oxygen, or argonâwhich are injected through the nozzle to significantly enhance the cutting process. These assisting gases can facilitate an exothermic reaction, releasing additional thermal energy that accelerates material separation. Oxygen cuts, for example, generate extra heat that enables faster piercing of thick steel, while nitrogen is preferred for producing oxide-free, high-quality edges on stainless steel, aluminum, and other reactive metals. Assist gases also improve heat transfer, blow away molten material, prevent re-solidification on the cut edge, and maintain cut quality. Selecting the correct assist gas is crucial in precise laser machining, as it affects cut speed, kerf width, and surface finish for applications from aerospace to automotive parts fabrication.
With an optimized combination of laser source, wavelength, assist gas, and operating parameters, industrial laser cutting delivers high precision, fast turnaround, and exceptional edge qualityâmaking it the method of choice for high-tech manufacturing, custom fabrication, and rapid prototyping industries.
The previous chapter explored the various types of lasers based on their beam formationâincluding different lasing pumps and laser mediaâlaying the foundation for understanding specialized manufacturing techniques. In this section, we turn our focus to the primary laser cutting methods. These advanced fabrication techniques are central to precision machining in industries such as metal fabrication, electronics, automotive, aerospace, and medical device manufacturing. Understanding these methods is crucial for optimizing material processing, achieving high cut quality, and selecting the best laser cutting service for your application. There are four primary methods of laser cutting: sublimating, melting, reacting (reactive), and thermal stress fracturing. We will also discuss Stealth Dicing, a specialized laser wafer dicing technique.
Sublimation is a phase change process where a material transitions directly from a solid to a gaseous state without passing through the liquid phase, similar to how dry ice vaporizes without becoming liquid. In laser cutting, this advanced process is driven by a high-energy laser beamâoften from a CO2 or fiber laserâthat rapidly heats the workpiece, causing immediate vaporization of the target material with minimal melting. Vaporization laser cutting is especially valued for achieving minimal heat-affected zones and intricate, burr-free cuts in sensitive applications.
The process begins by forming an initial keyhole or kerf in the material. The localized focus of the laser increases absorptivity, enabling even faster vaporization. This produces a high-pressure jet of vapor, which ejects debris and further deepens the cut. The result is precise, narrow kerfsâcritical for applications demanding tight tolerances.
This method is particularly effective for cutting materials with low vaporization energy, such as plastics, textiles, wood, paper, foam, and thin films. Industrial users often choose vaporization cutting for non-metal materials where edge quality, fine detailing, and minimal post-processing are essential.
Unlike sublimation, the laser melting processâalso referred to as fusion cuttingârequires significantly less energy, roughly one-tenth of what's needed for vaporizing materials. Here, the laser beam heats the substrate until it melts, after which a high-velocity jet of assist gas (such as nitrogen, helium, or argon) blows the molten material from the kerf. These inert gases ensure that the process remains free of chemical reactions, producing oxide-free, clean cuts with tight tolerances and minimal dross.
Fusion cutting is ideally suited for non-oxidizing or active metals, including stainless steel, titanium, and aluminum alloys commonly used in aerospace, medical, and electronic enclosures. This method maximizes cutting speed, reduces heat input, and prevents discoloration or warping, making it a top choice for laser CNC machining services seeking high-volume production efficiency and superior part finish.
Advantages: Minimal thermal distortion, excellent edge quality, and the ability to process reflective or thin metals.
Reactive laser cutting, also known as flame cutting or oxygen-assisted cutting, employs a reactive (typically oxygen) gas to amplify the cutting process. The process starts with the laser melting the material. Simultaneously, a stream of pure oxygen is directed through a coaxial nozzle onto the cut zone, where it reacts with the molten metal in an exothermic reaction. The heat generated by this chemical reaction provides about 60% of the total energy required for the cut, significantly boosting cutting speed and efficiency for thicker materials.
Although reactive cutting is energy-efficient and enables higher processing speeds compared to inert gas cutting, it often leaves behind a layer of metal oxide slag or dross on the cut edges. Proper post-cutting processes, such as deburring or surface finishing, are sometimes necessary to achieve optimal part quality.
This technique is widely used for cutting thick carbon steels, titanium steels, and metals that are easily oxidizedâ industries such as heavy equipment manufacturing and structural fabrication benefit significantly from its speed and cost-effectiveness when laser cutting metal plate and sheet.
Considerations: Suitable for applications where minor post-processing is acceptable or where oxide-layer formation does not affect component performance.
Thermal stress fracture, also called controlled crack propagation or laser scribing, utilizes a laser to initiate a keyholeâabout one-third of the material's thicknessâcreating intense, localized heating. The rapid temperature gradients induce compressive and tensile stresses that, upon cooling (sometimes aided by coolants), cause the material to fracture cleanly along the laser's path. This process requires precise control of laser parameters such as power, scanning speed, and pulse duration for optimal results.
Thermal stress fracture cutting is mostly used with brittle and hard materials, such as glass, ceramics, and certain composite substrates. CO2 lasers are particularly effective, thanks to their infrared wavelength of 10.6 ”m, which is well-absorbed by nonmetals. This method is ideal for industries requiring precise cutting of wafers, tabletops, optical components, and microelectronics substrates. However, not all materials respond equally, so absorption characteristics at specific laser wavelengths must be evaluated during process selection.
Industrial Benefit: Lower power requirement compared to vaporization, efficient for rapid prototyping, semiconductor manufacturing, displays, and photovoltaic cell production.
Stealth Dicing is a specialized laser wafer cutting technology, originally introduced by Hamamatsu Photonics, and is frequently used in the microelectronics and MEMS (Micro-Electro-Mechanical Systems) industries. This advanced process forms the initial kerf or scribe line inside the material using a focused, short-pulsed laser beamâcommonly a diode-pumped solid-state (DPSS) or UV laser. Stealth Dicing is a dry cutting method, meaning the process produces minimal debris and avoids the molten edges and contamination typical of traditional saw dicing, making it highly desirable for semiconductor manufacturing and high-precision applications.
Key advantages include reduced chipping, less kerf loss, increased wafer yield, tighter line widths, and higher throughput. Stealth Dicing is often chosen for cutting silicon wafers, sapphire, gallium nitride, and advanced ceramics used in integrated circuits and LED manufacturing. The clean, precise nature of this method is central to quality assurance in modern microfabrication and die singulation processes.
If you are evaluating laser cutting technologies for industrial, commercial, or engineering purposes, consider how each method aligns with your application-specific requirementsâsuch as material type, thickness, required tolerances, and desired cut quality. An expert consultation with a precision laser cutting service provider is recommended to determine the optimal method for your project and ensure the highest quality results.
Various techniques can be used to create a hole with a laser, classified based on the movement of the laser beam relative to the workpiece. Each method offers its own set of advantages and disadvantages.
In this type of laser drilling, a single laser pulse with high energy is used to create a hole. This single beam laser focuses on a single location until the material melts layer by layer. The melting process is done efficiently and in a short amount of time, which makes this process desirable to produce multiple holes quickly.
In percussion drilling, the diameter of the laser beam matches the diameter of the hole being created. Unlike single-shot drilling, which uses a single laser pulse, percussion drilling employs successive low-energy pulses to remove material. This process involves 4 to 20 pulses, depending on the material's depth and the laser beam's properties, to fully penetrate the material. This technique is efficient for working with thick materials and quickly producing multiple holes.
In trepan laser drilling, the laser beam spot size is much smaller than the diameter of the hole being created. The process begins by making an initial hole, after which the laser beam moves around the perimeter of the hole to gradually expand it to the desired size. This technique is more efficient for drilling large holes compared to single-shot and percussion drilling methods. Although trepan drilling is slower, it offers improved metallurgy and hole geometry.
Similar to trepan drilling, this method employs a moving laser beam to drill through a material, but it does not require an initial hole. Instead, the laser beam rotates relative to the workpiece, mimicking the action of a conventional drill bit. Rotation is achieved using a spinning dove prism or other optical systems driven by a high-speed motor. The quality of the holes produced is comparable to those made by trepan drilling.
Initially, laser cutting involved manually positioning the workpiece for each cut. The process required moving the piece, making a cut, removing the laser, and then repositioning for the next cut. At that time, CNC programming and other technological advancements were not available. Todayâs laser cutting technology has eliminated the need for manual positioning, using computer-controlled equipment to make precise and efficient cuts quickly.
The main types of gantry laser cutting machines are typically made of aluminum and feature a long horizontal bed with a gantry positioned above it. These machines can be programmed to perform multiple cuts in a single pass, using either fiber optic or CO₂ lasers. Gantry machines employ CNC-controlled programming to achieve efficient, accurate cuts quickly and easily. In contrast to manually operated machines with footprints ranging from 8 to 16 feet (2.4 to 4.9 meters), gantry machines have a more compact footprint of 4 to 8 feet (1.2 to 2.4 meters).
In this configuration, the laser cutter stays in a fixed position while the material surface moves. This eliminates the need for laser movement, resulting in a simpler optics system compared to other setups. However, this method is slower and typically suitable only for cutting flat materials.
This setup contrasts with the moving material configuration by using a stationary material and a movable laser cutter. As the laser moves continuously, the beam length must be adjusted regularly to compensate for beam divergence, which can affect cut quality. To address this, re-collimating optics and adaptive mirror control are employed. This configuration is the fastest of the three, as controlling the movement of the mirrors is more manageable.
In a hybrid system, the material moves along one axis while the optics move along another. This setup integrates the benefits and drawbacks of the previous two configurations. A key advantage over the flying optics system is that the hybrid system maintains a more consistent beam path, which helps reduce power losses.
CNC laser cutting employs a high-powered laser beam to mark, cut, shape, engrave, and form materials with precision. This technique is highly accurate, capable of creating small holes and intricate designs. Like other CNC machines, CNC laser cutters use G codes and M codes for programming, which direct tool movement and performance.
In contrast to traditional CNC machining, CNC laser cutters operate non-contact and are thermal-based. The laser head, equipped with a focusing lens and nozzle, directs high-intensity light onto the workpiece to melt and cut it. Compressed gas flows through the nozzle to cool the lens and remove vaporized metal.
Types of CNC Laser Cutting Machines include:
5-axis laser cutting allows the workpiece to tilt and rotate on the table, enabling the laser to access three-dimensional components and cut or drill curved surfaces at challenging angles. This capability reduces the need for frequent workpiece adjustments, minimizing setup time and reducing the potential for errors associated with multiple setups.
A rotary laser cutter features a rotating device that positions the workpiece to cut along curved surfaces. The motorized rotary attachment enables the workpiece to rotate during the cutting process, allowing for 360-degree cuts and engravings on pipes, tubes, bottles, elliptical tubes, and D-shaped items. This technology excels in placing intricate designs, logos, patterns, and information on curved surfaces, all while maintaining high efficiency and precision.
The term "small laser cutting" or "small geometry laser cutting" refers to the process of cutting intricate and small design features. These cutters are specifically used for projects where regular cutting methods fall short, especially when fine resolution is required. This technique is ideal for parts with features smaller than the width of the kerf.
Small geometry laser cutting offers exceptional precision, enabling the creation of delicate designs with high tolerances. The choice to use small format laser cutting depends on the material thickness, as larger laser cutters can negatively affect the final product. Additionally, small format geometry laser cutters are chosen based on the feature size, which can be smaller than a kerf of 0.1 mm (0.0039 in).
Large format laser cutting is employed when working with oversized features or projects that exceed the typical workspace dimensions. Large format laser cutters are designed to handle materials of considerable size, with workspaces often measuring up to 3.2 m by 8 m (10.5 ft by 26.25 ft).
Flatbed laser cutting systems are used for large format cutting and come with bed sizes ranging from 1.3 m by 2.5 m to 2 m by 3 m (4.3 ft by 8.2 ft to 6.56 ft by 9.84 ft). These systems facilitate the automatic cutting and engraving of large materials by allowing them to be placed directly in the processing area.
Flatbed laser cutters are large format machines designed to cut a variety of materials, including metals, cloth, wood, and more. They can handle either a single large feature or multiple smaller features on a large piece of material. These cutters feature a spacious, flat horizontal surface for material placement. The laser is housed in a mechanism that moves along the sides of the bed, with the laser itself moving back and forth over the cutting surface.
Flatbed laser cutters can utilize CO₂ fiber, or crystal lasers. The choice of laser type depends on the material being processed: CO₂ lasers are typically used for non-metallic materials, while fiber lasers are suited for metals. Additionally, flatbed laser cutters can be configured to continuously feed materials as part of a production or assembly process.
Galvo laser cutters use mirrors to deflect the laser beam, allowing it to move in various directions by rotating, adjusting, and repositioning the mirrors. The operation of galvo laser cutters is based on a galvanometer, which detects and measures electric current through the movement of a magnetic field.
A galvanometer in a galvo laser system directs the laser to the marking surface using a series of mirrors. This design enables galvo lasers to complete the engraving process much faster than traditional lasers, which move along the X and Y axes at slower speeds. By rapidly repositioning the mirror angles, galvo lasers can mark larger areas of the workpiece at a higher rate.
There are numerous laser cutting machines available in the United States and Canada that are crucial to modern industries due to their precision and versatility. These machines enable the efficient fabrication of intricate parts and components, fostering technological advancements and economic growth. Below, we explore several leading laser cutting machines and their manufacturers.
Popular models: TruLaser 3030, TruLaser 5040, TruLaser 5030 Fiber
Features: The Trumpf TruLaser Series is celebrated for its superior cutting performance, cutting-edge laser technology, and advanced automation capabilities. These machines use fiber laser sources that provide exceptional cutting speeds and efficiency, particularly for thin to medium-thick materials. They also offer intelligent automation features, such as automated loading and unloading systems, to enhance productivity.
Popular models: LC-3015, LC-4020, LC-1212 Alpha
Features: The Amada LC Series is renowned for its precision and reliability. Equipped with high-power lasers and advanced cutting controls, these machines handle a variety of applications and material thicknesses with ease. The LC Series often includes proprietary technologies, such as the AMNC 3i control system, which offers user-friendly interfaces and enhanced cutting performance.
Popular models: ByStar Fiber, ByStar Fiber 6225, ByStar Fiber 8025
Features: The Bystronic ByStar Series is known for its high-speed cutting capabilities and energy-efficient fiber laser sources. These machines typically feature large working areas, ideal for processing big sheets and plates. Bystronic's innovative cutting heads and intelligent control systems make these machines popular for their precise and rapid cutting of various materials.
Popular models: Optiplex 3015 Fiber III, Optiplex 4020 Fiber III, Optiplex Nexus Fiber
Features: The Mazak Optiplex Series is distinguished by its advanced fiber laser technology and robust construction. These machines deliver excellent cutting performance across a range of materials, including steel, aluminum, and copper. Features such as Mazak's Intelligent Setup Assistant and PreviewG control technology enhance usability and productivity.
Popular models: CL-960, CL-940
Features: The Cincinnati CL-900 Series is known for its powerful laser sources and versatile cutting capabilities. These machines often come equipped with high-speed shuttle tables for efficient material handling, reducing downtime between cuts. The ProFocusâą Laser Cutting Head and Touchscreen HMI offer intuitive control and precise cutting performance.
Keep in mind that the popularity of these machines may vary depending on industry requirements, budget constraints, and regional preferences. Additionally, new models and advancements in laser cutting technology may have emerged since this update, so it is advisable to research the latest options available on the market.
Laser marking involves creating marks on a workpiece by cutting its surface at a shallow depth or inducing chemical changes through processes such as burning, melting, ablation, or polymerization. Similar to laser cutting and laser drilling, laser marking is a non-contact process, eliminating issues like tool wear and unwanted surface hardening. Additionally, laser marking does not require inks, offering an advantage over traditional printing methods. Various types of laser marking processes are summarized below.
This process involves selectively removing areas of a coating layer previously applied to the surface of the workpiece. The removed regions contrast with the remaining coating, making them clearly visible. This type of laser marking is typically used with special films and coated metals.
This method involves cutting the surface of the workpiece to a specific depth, typically using the laser vaporization process. The main advantage of this technique is its ability to operate at high speeds.
Thermal bonding involves fusing additional pigmented materials, such as glass powders or crushed metal oxides, onto the surface of the workpiece. The laser's heat melts these materials, creating a bond with the surface.
Annealing involves using a laser to heat specific regions of the workpiece. The applied heat causes the metal to oxidize, producing various colors like black, yellow, red, and green.
Carbonizing breaks the plastic bonds between polymers, releasing hydrogen and oxygen and resulting in a darker color. This process is used on plastics and organic materials.
Foaming is typically performed on plastics, where the laser destroys and vaporizes color pigments and carbon, causing the material to foam. This technique is used to create lighter-colored markings on dark-colored materials.
Staining induces chemical reactions on the workpiece's surface, with the reaction products exhibiting different colors.
Laser drilling is extensively used in aerospace, automotive, electronics, and tool machining industries. Here are the main advantages of using lasers for drilling.
Laser drilling eliminates the need for physical cutting tools, which means there is no issue of tool wear or damage. Unlike conventional drilling, where drill bits can become dull and slow down the process while generating excess heat, laser drilling avoids these problems. This prevents distortion of the material and maintains its mechanical properties.
Laser beams can be precisely focused, allowing for the accurate drilling of small holes that conventional methods cannot achieve. The depth of the holes can be finely controlled, even at the micro-scale. Additionally, the process is digitally controlled through CNC systems, ensuring that all parameters are automatically regulated to produce consistent and repeatable results.
In precision manufacturing, secondary processes like deburring are required to remove surface irregularities, metal spurs, raised edges, slags, and dross. Even advanced techniques such as laser cutting can produce dross or thermal burrs, but compared to conventional cutting, laser-cut parts generally exhibit superior edge quality. This reduces the cost of secondary processes, particularly deburring, which can account for up to 30% of operating costs.
Laser drilling allows for creating very deep holes with small diameters without issues. Conventional drills can overheat, wobble, and break due to torsional stress when drilling such holes. Lasers, on the other hand, create no frictional resistance and are only limited by the laser generator and optical systems used.
Lasers are effective for cutting and drilling materials that are challenging for conventional machining. They can handle high-strength metals like titanium and steel superalloys. Additionally, lasers are used to cut crystals, ceramics, and even diamonds due to their ability to achieve controlled fractures.
Drilling speeds with lasers depend solely on the configuration of the optical system and the movement of the cutting head, with no need for tool positioning against the workpiece. The complexity of the profile to be cut has minimal impact on the incremental cost of operating the machine.
As most of the molten material is expelled by the assist gas, there are no residual stresses along the drilled edges. This results in a clean, mechanically stable cut.
Despite these advantages, current laser drilling technology cannot entirely replace conventional methods. Here are the main reasons why.
Laser cutting machines are often significantly more expensive than waterjet and plasma cutters. The return on investment may not always justify the higher initial costs.
Operating a laser cutting machine requires specialized technical knowledge due to the complex range of operating parameters. Additionally, COâ and crystal lasers need expert attention to restore them to proper working condition if misalignment occurs.
Laser cutting demands highly precise movements, especially for applications requiring microns of accuracy. Two factors influence this precision: the accuracy of the control system and drivers, which must deliver precise signals to the high-resolution drivers, and the dimensional accuracy of the laser cutting components. Ensuring accurate mating of linear guides, lead screws, and other transmission parts, often achieved through deburring, is crucial.
The depth of cut is influenced by various parameters, with power being the most significant. For the same power rating, plasma cutters can achieve deeper cuts than lasers. Common industrial laser systems with power ratings above 1kW can cut carbon steel up to 13 mm thick.
While plasma and laser cutting are both cutting processes and may seem similar, they are fundamentally different in their application and principles. Both methods were developed in the mid-20th century and have since evolved to meet the demands of modern manufacturing techniques.
Laser cutting involves using amplified laser light to cut materials with exceptional precision, thanks to CNC control. The process focuses laser light through optics, concentrating it to a fine, intense beam that melts and cuts through the workpiece. During this process, the material is burned, and an assist gas or vaporization removes the waste material.
Plasma cutting is a technique for cutting electrically conductive materials using a jet of hot plasma combined with oxygen or nitrogen gas. This method can handle even rugged or tough materials. Plasma cutting is limited to materials that conduct electricity, including aluminum, stainless steel, steel, brass, and copper. The cutting plasma is a highly conductive, ionized gas that reaches extremely high temperatures during the process. Although plasma cutting tools operate similarly, the specific type of tool used depends on its temperature.
Plasma cutting tools operate at temperatures exceeding 40,000 degrees Fahrenheit (22,200°C). When integrated with CNC machining, this process produces parts that often require no additional finishing or machining. Unlike laser cutters, plasma cutters emit radiation, which necessitates the use of protective clothing and safety glasses or goggles for operators.
The primary difference between plasma and laser cutting lies in their energy sources: plasma cutting uses a plasma gas, while laser cutting relies on a focused beam of light. Plasma cutting also involves some safety concerns due to the radiation it emits. Despite their differences, both methods are efficient and precise, each excelling in its own way based on how it performs the cutting process.
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