The Best Examples of Laser Cutting in Electronics Projects

Laser cutting is relatively cheaper than 3D printing and injection molding and for engineering projects, it is best to go with the cheaper option. In the field of electronics & engineering, you often require precise cuts to ensure the proper functioning of the prototypes or products. And Laser cutting is known for delivering such accurate results that too at cheaper rates. Moreover, you can also achieve a level of consistency if you are making the cut many times.

And just writing it won't give you a proper idea.

Let's see some of the electronics projects executed using a laser cutter and why did the inventors use laser cutting:

Nixie Clocks

RobG, a leading market leader adopted the laser technology to cut the clear acrylic to mount the nixie components and let all of that electronic design come together. For this use case, the design was easy to achieve with laser cut parts. There are only two simple pieces, a back and a front. No sides. Basically, this is a tabletop clock. Therefore, it does not need much coverage as regular electronics. This leads to fast cutting time which eventually is an important consideration while creating a product to sell.

Nightlights

Jakob Griffith created a set of simple plugin nightlights. He created everything, from the printed circuit design to the artwork attached in the acrylic, and the final assembly. He started the project keeping the laser cutting tech in mind rather the other way around. With the help of laser cutting, he was able to do all the detailed art-work in a few hours which might've taken days with 3D printing and other alternatives.

WITCH-E Emulator

Harwell WITCH is a renowned instrument to teach computing and a milestone in computing history. The WITCH-E project started by Dave Anders studies the engineering characters of the Harwell WITCH and try to extract its educational value. The team has a common motto to accumulate informative materials in a form of videos, writing, and tools such as WITCH-E replica and emulator.

So, when Dave was working on a prototype he used laser cutting in order to make numerous iterations of custom designs in an inexpensive way. It was important to have the proper layout as electronics were to be mounted on it.

Pro Tip: You can also start your very own small project in your basement or garage and for the success make sure you are using quality parts e.g. Mazak Parts, Prima Parts, etc.

Music Devices

Nathan Walker thought of building devices that makes it easy to perform and record music in a better way. After facing hurdles in the initial stage, he started looking for the available options. When he didn't find an appropriate option, he came with a solution. Which was a headless Linux box with a DAW which starts working as soon as you turn it on. You can plug in any type of keyboard with USB or traditional MIDI output. This way, you can instantly access great synths and piano sounds. In this, there are faders and knobs to control anything in DAW. Therefore, it is a kind of dynamic change. While installing the faders, knobs, and buttons, Nathan wanted a lot of fine details. He wanted them to fit perfectly through the holes. To make it possible, he chose the laser cutting rather than an injection mold.

Fri3D Biped Robot

This biped robot is one of the main projects at Fri3D camp located in Belgium. Based on Otto bipedal design, its face is the animal shaped badge given to attendees that perform double duty as the brains for the build. The version is laser cut out of MDF but imagine this cute badge in different acrylic colors.

MeArm Robotic Arm

The MeArm Robots Arm is considered as the world's most accessible learning tool when it comes to engineering with the smallest and coolest robot arm. This robot arm comes as a kit and its parts are given proper shapes using laser cutting. With the help of a screwdriver, you easily gather its scattered parts and build yourself a robotic arm. A great source of information for anyone new in the world of programming, electronics, robotics, and engineering.

You can also embark your engineering journey with a project using laser cutting technology and the ideas mentioned above. It's a cost-effective solution with cutting-edge results. You can try searching Mazak parts, Prima parts to find suitable components for your engineering project!

Source:- https://www.sooperarticles.com/business-articles/industrial-mechanical-articles/best-examples-laser-cutting-electronics-projects-1723750.html

How to Achieve Burr Free Laser-Cutting

If you work at the laser cutting shop, you would notice that operators often offload the metal sheet of cut parts. After that, they would pick up the cut pieces from the nest for clean edges to make the sheets ready for the next operation.

Mostly right? But sometimes, you would notice that burrs on the surface still remains. It may vary from minor to major in size but with some precautions, you can reduce it. In order to discover the perfect setting, it is important for operators to know about the process in which a laser cutting beam, support gas, and workpiece get in contact to create perfect cut edges in the product.

Achieving a burr-free laser cutting is no longer a magic. It’s a strategy that revolves around the proper operation of laser parts which you need to understand thoroughly to resolve it. Let’s see how. 

Which Parameters to Check?

In general cases, the modern machine controls the laser beam elements. Like the beam profile and beam power. The beam focus consists of a particular grade, thickness based on optical focus.

To match the true focus position on the workpiece, automated technicians usually check a number of parameters including beam alignment, delivery system, centering the nozzle, focus position, etc.

If the operator observes a burr at the bottom of the cut part of the stainless-steel sheet, then firstly the operator needs to slow down the cutting speed of the laser beam. You can justify the reaction because in his perception, cutting speed is too high and the problem might have arisen from that. 

Once the operator has slowed down the cutting speed and the gas pressure, he would find a bigger burr. Therefore, the creation of burr depends on how the beam, material, and gas interact. And once you understand their interaction, you would understand the creation of burr.

The Burr Formation Process

While you work with the laser machine, there’s an intense amount of energy emerging out of the laser beam. That brings the metal’s temperature above its melting point. Hence, metal exceeds the melting temperature, during this, a strong force of gas removes the metal from the kerf. When you use nitrogen, the cutting procedure totally depends on the beam’s energy to melt the metal. But when you use oxygen gas to cut the carbon steel, it seems that hot metal interacts with oxygen that creates an exothermic reaction with added heat.

In such cases, they form the burrs due to the molten metal which solidifies before removing. That solid material would remain tougher at the bottom of the kerf, eventually forming a burr.

But what hardens the metal before you remove it?

Gas Kinetics

The operator should ideally alter efficiency, quality, and cost when nitrogen gas is concerned. Nitrogen can reach up to 50% of the variable costs. Therefore, it is important to control the consumption of such gas in laser cutting. Consider using Trumpf laser parts in order to maintain quality outputs. Make sure to select the smallest Trumpf laser nozzles to attain the desired quality of performance.

It is important to note that when it comes to supporting gas flow, nozzle size and diameter would make a big difference. When deciding, go for the smallest Trumpf laser nozzle size as they will get you a good quality of laser cutting without any burrs. Eventually, you can increase your flow rate with good molten metal separation without going high on pressure.

Slow is never better

The logic of “lower and smaller” diameter of nozzle and gas pressure is not applicable to the cutting speed. Hence, while you slow down the cutting speed, you would end up welcoming more heat than required in the kerf. Along with this the temperatures also rises and cause vaporization which disturbs the gas flow. As a result of it, this disturbance creates more burrs which make the quality even worst. You need Trumpf laser nozzles to ensure the proper interaction of cutting beam and gas which is the best way to avoid burrs.

Additionally, the operator can also save the material from burrs by increasing the cutting speed precisely. This increase in speed would minimize the heat and the ablation while restoring the gas flow dynamics to its appropriate state.

Carbon Steel Cutting by Assist Oxygen Gas

While shifting to oxygen cutting for carbon steel, the exothermic reaction needs to be at an accurate level because here, the oxygen purity level will play a crucial role. It is common that oxygen-cutting carbon steel benefits from a higher level of oxygen gas purity. We can increase the cutting speed by 30 to 40 percent if we work with 99.95 percent of oxygen global purity.

Concluding

Burr-free laser cutting is all about ensuring that the beam parameters and gas dynamics work in synchronization. Moreover, you also need to ensure that you are using superior quality laser parts like Trumpf laser parts for the best and burr-free laser cutting.

A detailed guide to eliminate the creation of burrs in laser cutting and achieve a stable process to produce smooth cutting edge results.

9 Proven & Useful Tips to Maintain Your Press Brakes

Press Brakes. The most important tool for any company running a production plant or factory. Even if you search for ‘Amada press brake for sale’ online there would be tons of options available there to choose from. They are expensive too, which means that they need intensive care and maintenance from your side to ensure its smooth functioning.

To help you maintain Press Brake machines for better-extended work life, we are bringing you some useful tips.

9 Proven & Useful Tips to Maintain Your Press Brakes

Wipe it out!

In general, it is advisable for all types of electronic machines and Amada machine replacement parts. Dust and dirt are among the worst enemies of these machines. Therefore, make it an essential step to regularly wipe down and clean your press brake machines. You can also use rust protectant to apply on the possible surfaces.

Lubricate Rails and Ball Screws

It is important that the back gauge is working and cleaned properly. To keep all the dust buddies away, lubrication is the key. Lubricate your rails and ball screws according to manufacturer’s schedule. Make sure that you wipe off all the excess lubrication after the application to make sure it does not collect debris and contaminants.

Don’t Forget Cooling Fans

They would be at the back of your press brake’s electrical cabinets. If I am not wrong, they are also known as vent filters. Dust usually blocks them. Therefore, make it a practice to remove them and clean out at least once a month or as needed. Make sure you keep the door closed except when you access it.

Clean the Lens Every day!

Lenses of your press brakes are the heart of these machines and Amada machine replacement parts. Even a small scratch on the lens can diffuse the laser. Therefore, make sure to use a clean, non-abrasive cloth to wipe off the dirt and clean the lens.

Pro tip: Keep a specific cloth set aside to clean the laser every morning before starting the machine to prevent any build-up on the lenses.

Cleanse the Surrounding Area

You don’t want the press brake machine getting dirty. Therefore, it is wise to practice cleanliness in the surrounding area as well. Make sure that you don’t have any junk lying around the machine area. It will help prevent further issues meanwhile increasing safety and productivity as well.

Tidy the Tooling

They collect dust easily. Make it a habit to change the wiping oil on a regular span. They make a huge difference. Make sure that you clean underneath your bottom die and wipe off the top part of the upper punch.

Seating the Press Brake Tooling

Whenever you load and unload your tooling, make sure that it is seating in a correct manner. Sometimes it becomes an issue that affects your press brake working. It is important that the upper tool is under a bit of tonnage to make sure it’s up where it’s needed. You also need to periodically check and verify the proper alignment of your tooling.

Inspect Your Machine

This should be a part of your regular maintenance cycle. Inspect and check your machine while cleaning to ensure if other parts are working fine. It helps you to monitor and solve the issues causing any unusual noises when you operate the machine. And when needed you can search for ‘Amada replacement parts online’ to buy the new ones. Check and tighten all your necessary bolts and connections on a monthly basis.

Park the Machine Right

At the end of the day when you are done with the working, park the machine in the bottom position. You can rest the beam down in the die or on blocks every night. With the cylinders and valves, it becomes much easier when the hydraulics don’t have to hold the ram up. Even if the press brake is brand new, pressure might bleed of holding this much weight.

Types of Sheet Metal Laser Cutting You Need to Know

Businesses dealing in laser cutting machines are blooming nowadays. The trend of sheet metal laser cutting is engulfing the market with their working methodologies. You get several options for new types of machinery available in the market to enhance the final results of cutting.

Specifying the laser cutting method types, these are the available choices varied by the industry requirements:

1. CO2 Sheet Metal Laser Cutting Machines
2. Fiber Laser Cutters
3. Direct Diode Laser or DDL

Let’s have an in-depth tour of all these methods to find out which one suits your standards and requirements.

1) CO2 Sheet Metal Laser Cutting Machines

This method is known as a traditional method. Many fabricators prefer to use this method, particularly for the +4mm sheet metal market. This type of method utilizes CO2 laser gas and electricity to create a laser beam. The fabricators then apply that onto the sheet metal. This method includes high-temperature operations which is one of the reasons behind the need for a higher capacity chiller unit.

However, due to the new introduction of new technologies in the sheet metal laser cutting and people are moving towards them. That brings me to the second type of laser cutting that is Fiber Laser Cutters.

Benefits:

Co2 Sheet metal laser cutting machines are widely used around the world and most of the fabricators are proficient using the same. Moreover, Co2 laser cutting machines are reliable and safe as they don’t come in direct contact with the materials causing next to no mechanical compression or stress.

2) Fiber Laser Cutters

Fiber laser cutters use optical fibers pumped with diodes to craft a solid-state laser cutting machines with no gas consumables. If you are working in this industry, then this type of cutters can produce precise results for you. When any fabricator is looking for a laser cutting machine, the main thing he is concerned about is efficiency. Fiber Precitec Laser Consumables provide speed, accuracy, and cost-saving results. One of the major things is that they contain a better focus capacity. Because of that, they can evaporate a material at pinpoint to make a smaller spot diameter, compared to CO2. This way you can make sure that the cut you produce is accurate and stable. This works well while you work with thin materials as well.

For instance, some of the Precitec laser consumables users use this technology to channel increased beam density and laser energy into the cut. With a shorter beam wavelength, you can produce a 90 percent shorter cut than a CO2 laser beam. It results in faster penetration of the material and the capacity to increase the operation by more than 30 percent.

They can also cut highly reflective machines such as brass, aluminum, copper. With a CO2 machine, there are chances of damage. Additionally, the fiber lasers are also well suited for other materials such as Hastelloy, Titanium, and Inconel.

Benefits:

According to a study, laser parts like LVD Strippit laser consumables provide manifold benefits. In terms of spending costs, fiber users can benefit from an 80 percent reduction in consumption of oscillator electrical power. And 100 percent reduction in laser gas consumption with a wall plug efficiency of 30 to 40 percent. They also reduce chiller unit electrical consumption to 80 percent.

In the fiber laser cutting, your maintenance costs would also gradually reduce because of lesser movements in its parts, lower consumption of heat, and longer diode life. It also reduces the sheet metal cutting machine maintenance because they do not contain bellows. Plus, there is no requirement for mirror alignment or replacement.

3) Direct Diode

The final method available for cutting sheet metal is a DDL technology. It is also known by the acronym DDL. In this method, the diodes are the key thing they use. Therefore, they eliminate the pumped fire system, used in fiber laser technology. Due to the elimination of the middle process, it makes it more efficient.

DDL is a reliable source method with enhanced beam quality. Machines such as Precitec laser consumables offer premium cutting performance which makes them ideal for users who need ultra-fast cutting and high-quality cutting results.

Benefits:

It enhances productivity by cutting thin material at a 20 percent faster rate. It is faster than fiber ones and it also works on thick materials with unsurpassed surface quality. The DDLs are capable of a wall plug efficiency level. That is of  40 to 50 percent more compared to 10% for a CO2 resonator. Also 15 to 20% for a disc resonator and 30-40% with a fiber resonator.

What is Your Choice?

The right choice of metal laser cutting is important to produce cutting-edge results which meet the requirements. Therefore, research, summarize your requirements, finalize the material and other aspects to choose the LVD Strippit laser consumables which are capable enough to produce fruitful results for your industry.

5 Tips to Safeguard Your Press Brake Without Sacrificing Productivity

Press brake is a machine tool for bending sheet material. These heavy machines can be risky to operators if used without appropriate safety. According to a study by the US Department of Labor report, every year more than 350 amputations were reported among press brake operators.

A major reason behind such injuries is the upgraded access of point of operation at front the of the machine. Plus, an operator’s ability to reach safely around the device to get to the operation point at a side of the machine. Moreover, the back-gauge system creates pinch points which creates a risk with the motion. If by any chance operator’s hand gets trapped between the material and frame, it might cause impalement or amputation.

Press brake operators can avoid such risky situations in just a few steps. Before digging brief into that part let’s have a closer look at some of the safety standards that every operator needs to know.

The Safety Standards

The industry follows the ANSI standard for press brakes. ANSI B11.2 is to safeguard method guidance. ANSI B11.19 for design criteria.  Looking at the history of these standards, the original B11.3 came as an approved standard in 1973. There was a revision in the policy in 2002. The current standard is B11.2 which was last updated in 2012. Amada machine replacement parts provide the highest possible safety standards for any press brake operator.

To make sure that you are well-equipped with all the safeguards, consider the below-given tips to practice safe sheet bending in your factory.

Use Awareness Barriers

It is human behavior to perceive red color as a warning sign/barrier. You can use signs like ‘danger’ or ‘warning’ at the back of press brakes in wide red letters. Because the backside of the press brakes cannot be wide open. There are possible risks lurking there. Reaching the die part from the back and a multi-axis back gauge moving with pinch points. If you wish to decide what can be put at the back of the equipment, it will depend on the local OSHA interpretation.

Barrier Guards to Rescue

Barrier guards can help you with the risk management of press brake. While looking for Amada machine replacement parts online, you must have come across the fact that barrier guard can be the most versatile part to provide a safety layer. You can use them at the ends of most press brakes. They are effective in mounting light curtains with added values as well. With barriers, you can have the openings for material to be fed into the die area. Although they do not allow hand-to-hand processing into that area.

Mount Light Curtains

Light curtains have been in the business since the mid-1950s. They contain a vertically mounted transmitter and receiver with spaced beams of the laser. It creates a flat sensing field. The key advantage is when human fingers, hands or a whole arm reach through that sensing field, the whole press system stops to avoid possible injuries. If you search the term ‘Amada machine replacement parts’ on the web, you will find many available options for light curtains.

One of the reasons that light curtains are a good fit for press brakes is that press breaks can be stopped during the mid-cycle quickly. With hydraulic press brakes, it is possible. On the other side, mechanical press brakes may not be able to deliver the same experience that swiftly. Mechanical friction clutch machines are also known for stopping slowly. Light curtain contains ‘function-tested’ operations. Before operating the press brakes enable these function tested curtains to ensure that they continue to provide enhanced protection.

Utilize Laser AOPD

This method is one of the newest entry into the safety category. It is included in the B11.2-2012 safety standards that now provides safety guidelines to manufacturers, dealers, and users to implement and practice these standards. This is an acceptable method of safeguarding hydraulic press brakes only per ANSI B11.3 with the collected manufacturers’ specifications. One of the most unique features of AOPD is that it can be mounted with zero safety distance, unlike curtains that should be mounted at a calculated safety distance. It is applicable only to hydraulic press brakes. You can find the same online. They are best suited for box bending, bending with flanges or where light curtains effectiveness is diminished due to excessive muting.

Are You Prepared?

If you are also a press brake operator, you might have an idea about how dangerous it can be while working with Press Brake machines. When your machine is safeguarded, installed and operated in a correct way, the safety of all the workers remains intact which eventually reduce your operation and insurance costs.

How to Maintain Laser Cutting Machines?

With the laser cutters, you can produce the most accurate and high-quality cuts for fabrication. In order to maintain the efficiency and consistency of these machines throughout, fabricators need to perform preventive maintenance on a regular base. After all the laser cutter is an expensive piece of equipment. The first tip is to avoid procrastination. Because the lack of maintenance leads to a lower quality cut without any perfection. To understand how laser parts can work more optimally, read the below steps to keep your laser machines up to date.

Never Leave the Laser Machine Unattended
One of the Laser Materials like acrylic is prone to catch fire when it goes unattended during the cutting process. There have been instances when people had to replace the whole laser cutting machine in cases of fire. To eliminate such cases, we need to make sure that someone is within 3 feet area all the time.

Keep the Lens Clean
Every fabricator has a different type of laser cutting schedule. Daily maintenance is one of the major things we need to make sure for the laser parts involved in the process. If you wish to replace any of them consider Mazak laser parts. They come with good quality features and provide an ample amount of cutting. One more thing to make sure that after the cutting schedule, check the lens and clean if necessary. As the top lens and mirror are right above the laser beam and exposed to a lot of dirt, smokes, debris, and fumes. With the dirty lens you might get:

• A need of lower speeds or higher power to cut.
• Uneven and blurry images.
• Damaged lenses

The simple way of cleaning the lens and mirror is removing it gently and cleaning both the sides with a q-tip or lens paper.

Clean out the Filters
With regular maintenance tasks, you need to maintain the filter as well. Based on its usage and the type of materials, you need to change the inner ‘pad’ pre-filer and clean the foam dust collector.

Here are the hints that indicate that you need to replace the filter:

• Smoke is collecting in the laser bay.
• Fire/flares in the bay.
• Odor emanating from the machine.
• The filter is dirty on both sides.

Here are the steps to follow to replace the filter:

1. Open up the machine.
2. You will see the inner filtration assembly inside. There would be a foam dust collector inside the metal mess. Since it catches the big dust particles, rinse this out in the sink and dry it out.
3. There would be a wrapped pad pre-filter on the outside.
4. You can buy new pre-filters and wrap them around.

Consider Warranties
Warranties are a key part of the buying process. If you are a fabricator and pursuing a maintenance contract or extended warranty, it is important for the purchasing department to have a complete understanding of points covered in it. Do the contract cover maintenance and parts? If yes then does it cover quality laser parts Trumpf laser parts? Is there any discount provided on any needed replacement part? How much more an emergency service call would cost without a contract? What are the possible limits of the contract?

Replace Charcoals
With the cutting, plastics, there are chances of developing odors. However, the pre-filer works the best to get rid of particle matter. But the Electrocorp also has 20 lbs of carbon particles. And they absorb the nasty smell. Eventually, the charcoal gets 'full' and doesn’t absorb fumes.

Some indications that you need to replace the charcoal:

• The smell of burning plastic is strong.
• Smoke sucked away.
• The filter is clean but the problem doesn't go away.
• The charcoal smells of fumes.

To replace the charcoal, pour out and throw out the old charcoal. Pour in cup-full of fresh charcoal while tamping down with a rubber matter or a wooden dowel to pack the charcoal.

Final Thoughts
Maintenance of laser parts is varied by its usage and type. There is no one-size-fits-all solution to properly maintain the laser fabrication process. And while you replace the laser parts, you can find several options from the web if you write queries like ‘Trumpf laser parts’ and ‘Mazak laser parts. The maintenance lessons result in a more consistent, reliable, and cost-effective laser operations.

How to Get Rid of Shearing Defects?

Shearing is a fabricating process used to cut metal sheets. The Shear blade machine consists of a shear table, blank holders, upper and lower blades. A back gauge is used to make sure that the cutting process is streamlined. When it comes to a perfect cut of the metal you need a high-quality shear blade like Amada shear blade which reduces the effects of variable sheet metal characteristics, internal stress, geometry to reduce the possible defects in the shear blades.

In this case, you need to take care of these natural effects. As they can make your shear blades defected and may reduce the final cutting quality of the product. If you work at the metal forming factory you must know that it is important to maintain your shear blades time-to-time. In this article, we have a list of variables used in this process along the solutions to get rid of possible shearing defects.

Cutting Angle
It is the cutting-edge angle of the blade. With two square edge blades, it requires higher cutting force than the upper blade. It is at an angle of 87°. And the lower blade is always at 90°. These are the ‘four-edge’ blades. Angled blades are called ‘two-edge’ blades.

Shearing Angle
This angle has a great effect on the shearing force. When you shear thin strips, this angle has an important effect on twisting. The shearing angle is less than 3°.

Blade Clearance
It’s the perpendicular distance between the shearing blades. The quality of results depends on plate thickness and material strength. If the cutting clearance is too small, the costs will be higher. If it’s too large, the result will be precise and large plastic deformation.

Clearing Angle
The clearing angle is fixed and set to 1.5°. The Blade ram is not perfectly vertical but is tilted pointing towards the backside to facilitate the piece separation.

The Shearing Defects and Solutions:

Twisting
In shear blades, this defect twists the plate with its axis. When shear narrow down the strips, it results in twisting. Other responsible shearing conditions are related to metal geometry. For example, high thickness and short length reduce the width, material characteristics like the soft material, uneven stress distribution and cutting parameters like high rake angle, high cutting speed etc.

To get rid of this defect it is recommended to lower the rank angle. This way, it would become useful to add an anti-twist device. Also, this option consists of a series of cylinders that push the plate against the top blade. This force applies when it corresponds to the plate thickness.

Poor Edge Quality
During the shearing process, the material initially deforms in a very small area, with a residual deformation. Then the upper blade penetrates the material where cutting is neat and clear. At the end of the shearing process, the material would give up. Because of that, the material cracks with a rough and irregular surface known as the fractured zone. This is often not perpendicular to the plate but a variable angle. You can improve edge quality by adjusting blade clearance, and keeping blade wear under control.

Crooking
In this defect, the surface stays flat, and a plate is curved along its plane. The responsible conditions include strip width, thickness, material strength, and previous cold rolling direction. The best way to reduce crooking is to use a smaller shearing angle and performed-cuts along rolling direction. Guillotine shear is another condition where blade ram supports its ends instead of the entire length.

Even during the shearing process the blade will become crooked because of the cutting force and will tend to open in the center. The best solution is to choose a shear with adjustable blade pads to keep it perfectly liner. You can opt for ‘Amada shear blades’ as they come with these specifications.

Bowing
In such a situation, the metal is no longer flat as this effect results in bowed sheet metal. Generally, it is related to cutting angle and plate strength. The best way to reduce this is by using a smaller shearing angle and hold the sheet metal with back support.

Does your shearing blades have experienced such defects? Amada Replacement Parts help you to avoid such types of defects for a period of time with their high tech functionalities. Although the regular maintenance and above-mentioned steps would help you to eliminate the shearing deficiencies.