Things You Must Know Before You Start Laser Cutting

Laser cutting, etching, engraving. It is one of the coolest ways to bring your designs to reality. It provides you results with precision, multi-layered lettering, and design.

Laser cutters are powerful, realistic tools to burn most things like wood, paper, plastic to create a design that you imagine.

So, before you buy a laser cutter, keep these five things in mind to make a precise choice.

The Main Choice: Laser Cutter

A typical laser cutter that most designers and engineers use consists of a 100W laser that have Trumpf nozzles. Between the laser’s extractor fan and sourced materials, your cost can reach $8000 to construct the whole setup. If you are just starting, you can even go for a smaller laser like 40W laser cutters available online. You can even search for parts like precitec nozzles or Trumpf parts online to setup the perfect product for your use.

40W laser cutter can help you with etching the designs you want on a thin place of birch plywood. You can also use acrylic material if you are looking for some cool opaque effects. Also, you can retrofit an old DVD players’ 5W laser into a working laser cutter if you have smaller use cases. It can do more than just etching a design on a piece of paper.

How to Source the Equipment to Build One?

In the digital age, you find many online options for your requirements. For nozzle parts, you can go for precitec nozzles, Trumpf nozzles online to source the best equipment for your business. Other than that consider referrals from your circle. They might also work best!  

What Materials to Choose?

You can not just pick any old material and start blasting it with a laser. There are numerous materials like polycarbonate sheets that produce thick, acrid smoke when coming in contact with the laser. Also, make sure that you don't go for cardboard as much as possible. Because the focused heat can cause fire easily when dealing with electrical equipment.

Birch plywood is a few millimeters thick but worth to add material; you can design simply with this material.

Your First Design

To find the best designs to start with, the internet is your bible. Of Course, it does not mean copying others' work. But you can get some cool ideas with which you can create your own designs. You get ready-made SVG files, DXF to put into a laser cutter software for printing.

General Things for Using Laser Cutter

Power: It defines the output power of the laser. It can be from 0 to 100%. Generally, high power to cut thick materials and lower power to engrave and cut thin materials.

Speed: It decides the movement speed of the laser head. To engrave and cut thin material, the speed is usually set to the maximum.

Frequency (Hz, PPI): It specifies the number of laser pulses per second. For instance, wood cuts are best at 500 to 1000 Hz. For acrylic, 5000 to 20000 Hz is the minimum requirement.

Focus: There comes a focus lens inside the laser head. It should be on the surface of the material or slightly below for most of the applications. Make sure that materials are at a certain distance from the lens. The exact distance depends on the type of focus lens.

There are so many types of laser machines that come with a motorized bed. You can move up and down to set the focus distance. And the position of the material surface should be also manually adjusted.

Parts: Make sure you are using the best brand parts like Trumpf nozzles, Amada laser parts, etc. to get the most accurate results.

It’s time to cut!

Don’t worry, it can take a few tries to find the ideal settings for your material. Make sure you change only one parameter in a test process. For example, do not forget to write down your current settings for future reference.

High-Powered Fiber Lasers: Are they Right for You?

For processing laser cuts with 0.25-inch to 4-kW laser, it can be a hurdle-less task for fabricators. Now when it comes to 12-kW or 15kW, they need high-powered fiber lasers.

And there are choices available in the market, but if you as a fabricator want to focus on thick metal cutting, only high-powered lasers are not the right choice. The 15-kW machines can do more tasks than cutting the thick material.

Overall, the major motive behind this laser technology is about decreasing process time in laser cutting. Let’s explore what these fiber lasers can do for a fabrication shop.

A Little Throwback to History

During the mid-2000s, high-powered laser cutting machines were a necessary tool for quick and efficient armor kits for US troop vehicles. After a few years with the debut of fiber laser technology, these giant machines were not in the trend anymore.

Why Fiber Laser Technology is a Hero

Fiber lasers produce a beam wavelength which is about 10 times shorter than the 10-micron beam wavelength with a CO2 resonator. It produces a higher power density which you add to the higher absorption rate will create a great cutting speed. This cutting speed outpaces that of a CO2 laser in less than 0.25 in.

It becomes easy for manufacturers to increase the power of these machine tools with the additional laser-producing modules, Amada laser parts, and Prima parts. That is the reason for the sudden surge in wattages. In fact, these systems can exceed 100KW in some instances.

Beam delivery systems cannot handle the power of 100-KW systems on their shop floors. Hence, each laser cutting system manufacturer is looking to produce a reliable cutting head which can deliver the fiber laser beam for an extended amount of time.

Recently, these machine tool developers are stepping into the production of cutting head optics which can modulate the beam size during cutting. Its development propelled fiber laser cutting machines from being a tool just for cutting thin sheet metal. When the cutting material gets thick, you need a wider beam to create kerf to remove the molten metal.

It is important for a company to look at the typical thickness range which makes up 80 percent of its work. Also, to make sure that your lasers are working fine, you need to install Amada laser parts and prima parts.

Here are the general rules to cut common metal such as steel, stainless steel, or aluminum with nitrogen:

• Up to 9 gauge—6 to 8 kW
• 0.25 to 0.75 in.—8 to 10 kW
• Over 0.75 in.—8 to 15 kW

Utilize the Material Exchange

The processing time on a fiber laser cutting machine is tied with the system’s ability to load sheets, unload cut parts, and skeletons. A fabricator does not gain any cycle time advantage if it has to wait for several times for the material movement. A lot of pallet changers are designed with CO2 lasers. It cuts slower rates compared to fiber lasers. They use hydraulics and can take 35 to 50 seconds to exchange a sheet.

The modern pallet changers rely on servo-driven technology. Here the automation is critical. When it comes to selecting pallet changer technology, fabricators should select one which can handle the thickest material they process.

Is High-powered Laser the right choice for you?

No, if your shop’s laser cutting workload is not expecting continuous growth. If it consumes only half of work shift, paying for a powerful laser to reduce the workload to a quarter of a shift won’t deliver a good return on investment.

If metal fabricators are maximizing their current laser cutting capacity, adding another shift, they can look at high-powered lasers. It is true when they use older laser technology. They can invest in a fast and efficient laser to reduce the number of laser operators needed.

Fiber laser cutting machines will grow in power if the cutting head and material handling can complement the power. You as a fabricator can take advantage of the power if you can feed these cutting machines for proper maintenance.

How to Achieve Burr Free Laser Cutting

Picture this scenario:

You are offloading a sheet of cut parts from the laser machine. From all these pieces, you will pick up a few pieces to reveal clean edges for the next step. And you leave the rest of the pieces with the burred finish.

In order to avoid such burred finishes, you need to know which parameters you exactly need to work on. Here are some handful of strategies to help you get the burr-free prints the way you want.

What Causes Burr?

During the process of laser cutting, the laser beam’s intense energy brings the metal beyond its melting temperature, and the powerful action of the assist gas leaves the metal from the kerf. When you use nitrogen, the cutting process relies on the beam’s energy to melt the metal. When carbon steel is cut, the oxygen interacts with the hot metal for an exothermic reaction. And that adds extra heat.

This is why you don’t need as much gas pressure to eject the material. With oxygen cutting, you have much lower pressure and slower dynamic flow of the gas. Overall, these burrs form from the molten metal solidifying faster than its evacuation. The solid material becomes a deposit at the bottom of the kerf. You can also control the burr by using the right nozzles, Mitsubishi spare parts, and Fanuc spare parts.

The Gas Dynamic

When it comes to nitrogen assist gas, operators need to make changes with quality, efficiency, and costs in mind. It can make up to 35 to 50 percent of the variable cost in laser cutting. Hence, it is important to control the overall consumption. When you set up cutting parameters, it is important to minimize the nozzle diameter. It is also essential to choose the smallest nozzle diameter that you can use to achieve the anticipated quality and performance.

After determining the smallest nozzle diameter, you need to determine the lowest possible pressure to obtain a quality cut with good molten metal separation with no burrs.

It is not the Speed

A burr-free finish is not something achievable with nozzle diameter and gas pressure. You also have to pay attention to the spare parts you are using. Make sure they are either Mitsubishi spare parts or Fanuc spare parts. Additionally, when you go too slowly, you might end up injecting more heat than needed in the kerf. And this might end up raising the temperature to an extreme level. Eventually, it causes vaporization which disturbs the gas flow

That disturbance, in turn, causes more burrs, not less. This means that an operator can make cut quality worse by slowing the feed rate.

You can prevent such events by increasing the cutting speed incrementally.

Consider Oxygen Cuts

When it comes to oxygen cutting for carbon steel, consider the exothermic reaction. It is a fact that with both CO2 and fiber lasers when you increase oxygen global purity to 99.95 percent or above, you can increase the cutting speed in production. Sometimes between 30 to 40 percent.

When an oxygen vacuum flask or cylinder has a drop in purity level, it is usually argon. It happens because the oxygen gets produced cryogenically in an air-separation unit, both oxygen and argon liquefy at similar temperatures.

When you add argon into it, it changes the exothermic reactions. It, in turn, affect the cutting performance. The exothermic reaction works in conjunction with the gas flow rate to burn and evacuate the molten material. If the molten material and oxidized slag aren’t removed effectively, it remains as a burr on the cut edge.

At last pumping

In most laser cutting systems, installers know to avoid elbows in the gas plumbing or to oversize the piping diameter to compensate for pressure drops. With downtime and gas not flowing to the laser, air penetrates and fills the pipe. It can cause problems when the laser is restarted for the next shift or operation.

Final Words!

In order to achieve the burr-free cut, the beam parameters and gas dynamics should work together to ensure the right amount of molten metal evacuates the kerf at the prime time.

Let's Discover the Behind the Scenes of Laser Cutters

Laser cutters help you produce products with high standards of precision. They are accurate and capable of providing you detailed and complex cuts. Overall, they provide you the freedom to design your products the way you want. You can cut materials using these machines according to your designs. And 99.9% of the time there are no chances of error.

These are fully automated and saves a lot of your production time. As your worker just needs to move materials, it leads to low material wastage with lower production costs. They can also provide laser engraving services to develop your projects and find a solution for your production. You can produce different depths and dimensions of your projects.

Let’s find out how.

The Working

It is a digital manufacturing technology, working on 2D vector files. The laser cutter has a laser resonator that depends on the cutting method, containing a mixture of a crystal body or glass fibers. When there is a force of energy applied to the mixture of the cutting process, the force sends the beam through different mirror lenses which focus on the laser.

The laser beam travels through the nozzle straight at the material. When it contacts the surface, it vaporizes the material in the shape of the vector file. There is a part of the material which melts with the laser, that is Kerf.

Basically, the laser beam is a column of very high-intensity light of a single wavelength or color. For a typical CO2 laser, its wavelength is in the infra-red part of the light spectrum. Hence, it is invisible to the human eye. The beam is about ¾ of an inch in diameter. It travels from the laser resonator that creates the beam on the machine’s beam path. These rays may bounce in different directions by several mirrors, or beam benders before they focus onto the plate. The focused beam will go through the bore of a nozzle right before it hits the plate. Also passing through that nozzle bore is a compressed gas like Oxygen or Nitrogen.

You can focus the laser beam by a special lens, or a curved mirror that takes place in the laser cutting head. It should focus on the spot of the laser material. The focus spot and density of the energy on it should be perfectly round, consistent, and centered in the nozzle. Just like when you use a magnifying glass to focus the sun’s rays onto a leaf, and that soon catches fire. Now when you think about when you focus 6KWatts of energy into a single spot, it can get extremely hot. The laser cutters containing Mazak parts or Bystronic parts can easily handle these high wattages for the best results.

This high-powered density can cause rapid heating, melting, and partial or complete vaporizing of the material. When you are cutting mild steel, the heat of the laser beam is enough to create an “oxy-fuel” burning process, and the laser gas will be pure oxygen, resembling an oxy-fuel torch. When you cut stainless steel or aluminum, the laser beam melts the material. The high-pressure nitrogen is the main component to blow the molten metal out of the kerf.

With a CNC laser cutter, laser cutting head can move over the metal plate in the shape of the desired part. Hence, it cuts the part out of the plate. A capacitive height control system can maintain an accurate distance between the end of the nozzle and the plate being cut. The cut can be affected by raising or lowering the focal point from just above the surface of the plate.

Other than these, many other parameters that work and affect quality. But when you control them properly, laser cutting gives a stable, reliable, and accurate cutting process.

The Endless Opportunities that come with it

You can make the most of this technology in various industries using high-quality laser cutters with Mazak parts and Bystronic parts. Whether it is a mechanical engineering, a technical firm or a creative space. For example, you can combine 3D printing and laser cutting. And after that, you get perfect for production needs and highly customized products.

Dual Source Laser Machines: Does your Business Need one?

Lately, there has been a huge rise in the number of dual-source laser machines. These machines can deliver better results in less time. The main reason is the demand in the market and the ease these machines provide. With such a laser system, you can have more options in one machine. You can choose a suitable laser source for your requirements.

If you are a novice in the laser cutter world, let me give you a brief on this. The dual-source system includes both CO2 and fiber laser sources in a single system. The CO2 laser has a versatile frequency that works well with wood, plastic, glass, marble, and more. But for engraving, you cannot rely on them. That’s when fiber lasers come in the picture. Now when you have a dual-source laser machine, you can switch out between these two sources according to the use and application. These machines are durable if used with the right parts like Amada parts or Trumpf replacement parts. The key is to invest in the right things.

The major benefit you get from this dual laser source is the versatility of the system. But is it really suitable for your business? Do you actually need one?

Let’s find out.

Are you using/planning only one source?

Based on your needs, you might use fiber laser less often than CO2. But there has been a surge in the applications of these fiber lasers and you will find yourself using these lasers more & more in the near future. Hence, having a dual source laser in place can prepare you for the future and you can add additional material processing capabilities. You can do all this without having to invest in the second machine.

However, it is important to remember that with the dual-source, you can use one type of laser source at a time. If you wish to use both simultaneously, then a dual-source laser machine is not the right choice for you. In such cases, opting for the systems separately would be a better option. You can make use of your single-use machines to the fullest too by using Amada parts & Trumpf replacement parts.

What’s your work area look like?

When you have limited floor space, a dual system makes perfect sense for you. It can be an appealing option having a system that can produce results of both CO2 and Fiber laser without expanding your physical workspace. Hence, if you have space for only one machine, a dual system would maximize the capabilities of your machinery.

What is the nature of your products?

After these factors, it is important to consider if the products you work on contain dual material. For example, does it contain plastic and steel? Or metal and leather together? In such cases, a dual-source can be the perfect choice for your application. With a dual system, you can engrave using both the CO2 and fiber laser in a single job.

Benefits:

Has the Best Features

When it comes to dual source laser machines, it allows you to process a variety of materials in a single operation. For example, the CO2 laser course is best for engraving, cutting plastics, wood, rubber, leather and other materials. And the fiber laser is correct for marking metals and staining plastics. You get a blend of these features in dual-source laser machines which makes it a perfect combo for your business.

Fewer Laser Jobs with High Output

Depending on your material, you can get your job done easily using a dual-source laser without manually changing laser tube, lens or focus. In such machines, you can easily assign sources to the associated software with just a touch and get the job done. You can do each of the laser applications, annealing marking, metal engraving, etc. in no time. It saves a lot of time providing you more flexibility to help you grow business.

Before investing in such a machine, it is important to describe your requirements. Decide if your system needs such a type of laser system or not. When you go into the purchasing process, ask the right questions to yourself and make sure you are prepared to make an informed decision.

Automated Laser Cutting: A Hit or Miss?

Automation has been a common factor in all the industries now. And the metal fabrication industry is just one of them. The common goals of a fabrication company include increased production speed and boosted capacity to meet the growing demand.

Can automation help you meet these requirements? Let’s find out.

Is Automation Right for Your Business?

It solely depends on your short-term and long-term needs. By applying laser automation, you get:

Speed: With automation in place, material loading speed accelerates up to 35%. 

Capacity: You can achieve the highest production results with your machine.

Consistency: With automated laser cutters, you can perform precisely and get everything (time between cycles, load and unload times) down.

Finding the Right Type

Loading/Unloading System: When you add such type of system with the existing machines, it enables them to function unattended for a longer period of time. You might see an increase in productivity by 2.8 times. It includes a single load and separates unload tables. It restricts you to one material type/thickness at a time, making it an ideal choice for batch productions where you require fewer changes.

Flexible Manufacturing System (FMS):

Such a system makes it possible to run a variety of material types and thicknesses without any assistance from an operator. FMS has multiple storage shelves that let you load materials into one or more laser cutting machines. These systems typically deliver a beam on-time of roughly 92% and 14.7 hours of cutting per day. They can be an ideal choice for small-batch productions and frequent material changes.

Your Initial Stage Configurations

The Types of Materials

With simple systems like the load/unload system, it uses a single table. With FMS systems, you can load a range of materials into different shelves.

The Number of Machines

A compact system can work well with the machines you already have. In the future, when you want to expand your business to a certain extent, a modular solution will be a more logical option. 

The key here is designing your system to handle a bit overcapacity. And you would not want to go overboard, as it might tie up too much operating capital.

The Considerations

Most systems have a maximum capacity of 1” sheet of the mild steel. You can design systems to run single sheets without using any transceiver which will give more flexibility. In case if you need parts automatically sorted, you can build some systems to cut parts from a skeleton, depositing them on a specific offload table or you can deposit them in a bin.

How would you like to control your automation system?

Load/Unload systems are typically simpler. They use a basic cell controller to load the program sequence-wise on your machine. An FMS will need a more sophisticated system which prioritizes tasks, manage inventories, provide data about the cuts, when, and more.

What type of material unloading system will you need?

There are so many options available which you can consider. It could be any of the following: fixed tables, scissor-lift tables, multiple offload tables, rail systems, and conveyors. Also, make sure you are using either Prima spare parts or Mitsubishi laser spare parts when converting to automated lasers.

The Challenges

Here are some of the challenges to keep an eye on:

• Labor: You will need highly skilled operators to monitor production if you want superior quality results.
• Morale: When your team supports the transition of production from manual to automation, it will help you become a greater success in the long run.
• Effects on Other Machines: If laser cutting is a bottleneck, it is important to make sure that operators and machines downstream are prepared to handle the increased production time, when your automated laser cutter is fully functional.
• Laser Parts: There are some medium quality parts available in the market which could seem like an economical choice but will hurt you in the long run. So, whenever doing the transition from manual to automation, make sure you are using Prima spare parts or Mitsubishi laser spare parts.

If you as a fabricator wish to accelerate the overall flow from automated laser cutting, it is important to choose the right laser machine with the right partner by your side to make this implementation a success for your business.

How to Maximizing Your Laser Production

With laser engraving and cutting system, there is one thing that comes as an absolute benefit: the speed. These systems render the fastest results to etch a pattern or cut the piece with the design. But when you have such a system in place, it is important to maintain efficiency otherwise it can hamper your overall growth. So, here are six hacks to help you with maximizing your Laser Production. 

1. Make a Batch

A basic thing to pay your attention to. When you print multiples at one time, it reduces production time. This can be possible in the cases when you require the same engraving or cutting on more than one item. When you engrave in batches, you can experience an increase of 37% in the time savings. When you are working in the batches, how many products would go in once depends hugely on the table size. You need to enlarge the page size in your graphic design program to match the full table size where you place your laser. In such cases, you can use a jig to space out the items. The output from any batch would be a result of using the right nozzle which includes a Trumpf nozzle or Precitec nozzles.

Adjusting Resolution

This is another factor to consider when you want to increase production. Especially in engraving jobs, it is important that the final image output is adequate. When you keep your DPI(Dots per inch) higher, it will take longer to engrave the item. And if your DPIs are higher, then the dots are going to be closer together. This will produce a detailed image, but it might take a bit longer time. If you lower your engraving resolution a bit, it can increase your time savings by 33% or more. The key here is to find the right combination of resolution and pattern which render achievable results with good quality in less time.

Color Mapping

Using color mapping can save your engraving time. For example, there is a design with three columns and in it, there are 30 names. At first, the laser will see it as one image and the laser head will travel over the white space columns to engrave the graphic. When you have a color mapping in place, it enables you to skip all the white space as it assigns each column a different color and an associated engraving order. This way, the laser will engrave one column at a time, traveling over white space. It will save you almost 43% time depending on the item you have put for the job. For better results of this technique, you can use a Trumpf nozzle or Precitec nozzles in the implementation.

Center engraving

This makes it easy to work with the various sized items, as you can create a custom template for each one. It allows the user to move the laser by hand to the center of the project. Set the center point as the new home position and the laser will utilize that point to properly place the graphic. Compared to other items it will save you a lot of time.

Pre-engrave Items

Customization is a great opportunity to give your business a new customer base. But singular jobs can prove to be very inefficient. Because if you load and produce the same design over and over in your engraving machine, it consumes a lot of your production time. To overcome this obstacle, you can pre-engrave and create an inventory of your popular items. This way you can just load pre-engraved material and save a lot of money & time.  Thus, pre-engraving can help you to engrave the same items in one go to decrease the production time. It becomes easy to pre-engrave the major graphics of the design onto a batch. Once the order comes in, you can simply use one of the pre-engraved boards back in the machine.

Using Job Manager

Using a job manager will help in keeping track of the regular jobs done in your laser machine. It becomes easy to streamline your laser processing workflow. It saves your time by giving you access to job time records, databases, status and more.

In a Nutshell

It is important to maximize your laser production for long-term production benefits. When it comes to laser machines, keeping these little things in place would help you eliminate unnecessary gaps in your system. Plus, an increased rate of the job will be your additional advantage.