CO2 Vs. Fiber Laser: Which one to choose?

Which is better technology? CO2 vs Fiber Laser is one of the common discussions in the manufacturing circle for many years.

Most manufacturers utilize both CO2 and Fiber technologies. They do so as they have noted the difference in technologies, abilities, and performance. Ultimately the selection of the technology comes down to the material you are cutting and its thickness.

The common thing between them might be Mitsubishi spare parts and Trumpf parts. However, Mitsubishi spare parts are superior.

Let’s know the CO2 and Fiber Laser process and their advantages and disadvantages.

1. CO2 Lasers

CO2 laser development dates back to 1964 by Kumar Patel. It is quite a convenient process even today. CO2 lasers are the high power continuous-wave lasers available at present. It is one of the oldest gas lasers available.

What is CO2 laser cutting?

In CO2 laser cutting, the light begins to process when electricity runs into a gas-filled tube. The gas tube has mirrors at both ends. One mirror is quite reflective and the other one lets the light come through.

The mirrors lead the laser beam to the material that needs to be slit. The gas is usually a blend of nitrogen, helium, hydrogen, and carbon dioxide.

Advantages of CO2 Lasers

• Good Finishing

 CO2 lasers can give you a finer edge on stainless and aluminum workpieces.

• It is Flexible

CO2 lasers can work across the range of non-metals and laser applications.

• Good With Thick Materials

Lasering a thick material is no more an issue with CO2 lasers. The CO2 lasers leave the finishing even smoother on thick materials than fiber lasers.

• Faster Process

The CO2 lasers slit the material faster in a straight line. Also, it offers a quick probing time from when the cutting is first started.

Disadvantages of CO2 Lasers

• Maintenance

Most of the components present in this technology need maintenance. This can not only disrupt your manufacturing process but also be expensive.

• Machine Size

The major issue with the CO2 cutting is its machine size. The machines are gigantic. Additionally, the CO2 tube requires much space. In a nutshell, it can occupy a big area. It is an issue when you are working in a small workshop or running a small business.

• Difficulty in Transporting

As it is a heavy and gigantic machine it is not transportable. Moving the machine to another place is a sluggish and costly process.

2. History of Fiber Lasers

Fiber Laser’s invention dates back to 1963 by Elias Snitzer. Yet, it took 2 decades to develop before they could be used commercially.

Even after hitting the market almost after twenty years, they are still away from being perfect. Though the first fiber laser was useful, it was not apt for heavy industry use as we see today.

What is Fiber Laser Cutting?

It is the heated cutting process that utilizes a high power density laser beam to melt, evaporate, and slit.

At the same time, high-speed airflow blows away the molten material, gaining on the cutting process.

The fiber lasers are constantly expanding their field. Though it is not perfect, it has become the hot spot of industry research and development. 

Advantages of Fiber Lasers

• Low Maintenance

Optic fiber transmission, without a reflector, is maintenance-free and can save a lot of maintenance cost. Its mass use of mirrors, bellows has a less amount of cost associated with maintenance.

• Speed

There is no comparison between CO2 and Fiber Laser in thin materials. Fiber lasers have double or triple the speed.

Numerous Varieties of Cutting Materials

One can use the fiber lasers on a range of materials like metal, non-metal, leather, wood, fiber. But, different materials might require different laser cutting techniques based on properties. 

Disadvantages of Fiber Lasers

• Finishing of Thick Material

One of the advantages of a CO2 laser is finishing on the thick materials, especially stainless steel and aluminum. Fiber laser technology is still far compared to the CO2 in this case.

• Flexibility

CO2 lasers are more flexible as compared to CO2 lasers. The CO2 lasers can slit a broad range of materials, especially non-metals. 

• Up to You

Like every other technology, these both come with strengths and weaknesses. CO2 is older and the Fiber lasers are gaining the market fast. With the speed benefits, the operating cost is also less than the CO2 lasers. 

Financial savings from the fiber lasers can be game-changing. But, you should choose technology based on material and other resources. Like if you need to work on thick material, CO2 lasers would offer better finishing. For the thin material, you should go with fiber lasers.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/co2-vs-fiber-laser-which-one-to-choose

Plasma Cutter Consumables: A Mini Guide

Today almost every industry requires a type of plasma cutter for a successful cut. It usually involves having high-quality parts for cutting edge marks. Behind the scenes, it requires a quality plasma cutter, proper handling methods, timely maintenance, and other motion control tools.

Often neglected are the consumables, i.e., plasma cutter components that wear over time and usage. You often forget to replace them, unaware that a faulty part can disrupt other components' progress too. What should you do to avoid it? 

 

Maintain the torch. It can ensure that Kaliburn plasma components are working correctly. But for that, you need to maintain all consumable parts in the plasma torch. 

 

What are those main components of a plasma torch? What is its durability? How to increase their shelf life? 

 

Let's find answers to these questions. But first, a layman introduction of Plasma cutter consumables. 

 

What is Plasma Cutter Consumable?

 

In simple terms, plasma cutter consumables are the components of a plasma cutter. This machine uses an accelerated jet of hot plasma to cut electrically conductive materials like steel, aluminum, brass, and others.

 

Components of Kaliburn Plasma Consumables

 

The torch and consumable parts together yield the plasma cutting arc. The main components include swirl ring, electrode, nozzle, shield cap, and retaining cap. 

 

They remain the same for all the consumables, including Hypertherm Powermax 45xp fine cut consumables and Kaliburn plasma consumables.

 

Swirl Ring

 

It is a small component in the torch. It channelizes the gas coming from the machine in different directions and temperatures. Additionally, it balances the flow of gas inward and outward. 

 

Swirl Ring acts as a protective layer and prevents the nozzle from burning or degrading rapidly. 

 

Electrode

 

The electrode is a slender, narrow piece of copper or silver and contains hafnium or tungsten. Its purpose is to carry current from the torch to the plate, which arcs the plate after passing through the stages.

 

Nozzle

 

The nozzle focuses the arc on the plate and cuts. As it remains in the middle of superheated gas, it may wear out sooner. Thus, the electrode's backend has a cooling device that helps in transferring the heat. 

 

FYI, a large opening nozzle is used for gouging and a small one for fine detailed work.

 

Retaining Cap

 

The role of the retaining cap is to hold all the consumable parts of a torch together. It is a component that wears out soon because of the heat on the ends. 

 

Shield Cap

 

As the name says, the shield protects the torch and other components from the molten metal or sparks. It takes over the brunt of fallout so that other components don't wear early. 

 

Durability of Plasma Cutter Consumable

 

Now that we know about the different components let's see how long they can last. 

 

The most affected are nozzle and electrode because of direct involvement with cuts and arcs. You should replace them simultaneously in a defined time frame. The other components, such as a swirl ring and retaining cap, are vulnerable to dropping and breaking. Replace them when any cracks appear. You don't need to replace the shield cap as long as you can clean the slag and ensure consistent airflow. Once the slag build-up is too large to remove, remember it's time to replace it. 

 

Tips to Prolong Life of Consumables 

 

Replacing consumables at the right time is essential. However, here are the three ways you can extend your plasma consumables' life. 

 

1. Cutting: Fine cutting requires a lot of focus work. A quick or slow cut from a wrong distance can not only make the work wrong; it can also wear your parts quickly. 

2. Installing: Ensure that the installation of components is proper as it would affect the functioning. See to it that tolerance matches the amperages and is well assembled. 

3. Monitoring: Keep track of the components and their wearing. If a part wears, immediately replace it with a new one so that other parts are unaffected. Try to change the nozzle and electrode frequently so that they don't hamper the cut quality. 

 Conclusion

 

Keeping a check on plasma cutter consumables and torch is essential. Besides, you should also maintain and replace them routinely. If not, they may cause a catastrophic failure.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/plasma-cutter-consumables-a-mini-guide

How Laser Cutting Works in Leather Industry

 From car seats to handbags, jackets, shoes, and others, leather is a widely used product in the market. Its design and flexibility make it easy to cut and shape into another. Technology has further made it possible to use leather for automobile seats, book bindings, fashion, and furniture.

The increasing application count highlights that the leather industry should replace the cutting process like stone knives and bone needles with laser cutting. Laser cutting is a popular technology and can enhance leather’s functionalities while maintaining quality.

Keep reading to learn more!

Laser Cutting

Laser cutting is a process of cutting metallic and non-metallic materials with a laser. You can use it for industrial or artistic purposes. 

How does it work? The cutter discharges a high laser beam, which then distorts the material and makes a cut.  

Role of Laser Cutting in Leather Industry

For making a leather product such as car leather, furniture, or shoes, you first need to cut the leather. Leather skin, being a non-uniform contour, makes it challenging to cut. Up to that, it requires a high level of knowledge, good observation skills, and high-quality tools like a laser cutter. 

Laser cutters provide high-quality cut in less time with the help of laser beams and computer technology. Generally, the CO2 laser beam focuses on the small spot. This focus then attains a high power density that converts photons into heat. The generated heat makes a hole in the material. Despite being at a high temperature, the laser cutter doesn’t deform the material. It is possible because of the cut seam that the hole produces.  

Processes Involved in Leather Industry

As leather needs to be cut in different shapes and sizes, laser cutting involves two different processes to accomplish the goals. The two approaches are nesting and cutting sequences. 

Nesting

Nesting means positioning parts in such a way that they throw minimal waste on cutting. However, it is not a suitable choice because it doesn’t guarantee the complete utilization of material. This uncertainty makes it challenging for large businesses to follow this process. Besides, a large-scale production might have to spend more than earn. The process involves a lot of challenges. However, to overcome it, the use of nesting software has increased. 

Cutting Sequence

Cutting sequence is a process that utilizes the shortest path to accomplish the cutting procedure. 

Along with processes, manufacturers like Trumpf spare parts and Bystronic laser parts also enhance the machine’s ability to engrave leather. 

Leathers Suitable for Laser Cutting

The four most suitable types are:

• Natural Leather: unfinished leather used for dyed leathers.
• Suede Leather: napped finish leather used for jackets, shoes, shirts, purses, furniture, etc. 
• Synthetic Leather: artificial leather used for upholstering, shoes, and others.
• Alcantara Leather: a synthetic material used in automotive.

Advantages and Disadvantages of Using Laser Cutting for Leather Industry

Advantages

• You can have clean and sealed edge cuts.
• Have high production speed to finish more work in less time.
• Produce high-quality products and intricate designs.
• Save cost as power used is less.
• Work with a piece of contactless equipment that doesn’t require manpower.

First, you need to choose a machine that has quality parts and features to leverage these benefits. Manufacturers like Trumpf spare parts and Bystronic laser parts provide high-quality products. Make sure to check them out.

Disadvantages

• You need experienced hands to operate the machine.
• The natural quality of leather changes
• While material burns down, flames occur. (Though you can solve it by keeping the machine in a ventilated area.)

Conclusion

It would be beneficial to have a laser cutting tool in your leather business. Its extensive list of features and benefits makes it an attractive tool. Yet, to purchase it and its consumables, always prefer quality manufacturers like Trumpf spare parts and Bystronic laser parts.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-laser-cutting-works-in-leather-industry

A Comprehensive Guide to Laser Cutting Technology

We use many variants of cutting processes in different industries. Laser cutting is not an exception. It is widely used for different applications such as metal, nonmetal, ceramic, or so. 

A technology that we looked up to as a conventional form of cutting has its own techniques and processes that provide a whole new range of possibilities for industrial applications.

Besides, manufacturers like Precitec Laser Parts and Prima Laser Parts leave no stone unturned, ensuring different lasers such as Gas lasers, Crystal lasers, and Fiber lasers make the cutting swift and fast. To help you understand it better, we have listed down different techniques and types of lasers.

Types of Laser Used for Cutting

Generally, there are three main types of lasers. They are:

1. Gas Lasers

Gas laser cutting is also known as CO2 cutting. It uses an electrical simulating, i.e., carbon dioxide mixture for cutting. 

The gas laser cutting has its roots dating back to 1964. Back then, the laser was not strong enough to cut metal. Though it is now, the nonmetals remain the specialty. The laser has a wavelength of 10.6 and is widely used in medical and industrial sections. 

For cutting metals such as steel and aluminum, it uses nitrogen. Given the consequences, it is wise to take precautionary measures and ensure that nitrogen is pure. If it is not, the metal may oxidize.

2. Crystal Lasers

The lasers use crystals made from nd: YAG 

(neodymium-doped yttrium aluminum garnet) and nd: YVO 

(neodymium-doped yttrium ortho-vanadate). The crystals are of a solid-state group and can cut both metals and nonmetals.

Crystal lasers have a wavelength of 1.064 meters, and you can use it for multiple industrial applications, including medical, dentistry, military, and manufacturing. 

The drawback of using a crystal laser cutting process is that it is made of expensive pump diodes. Up to that, they have a shorter life expectancy than other lasers available in the market. The service life is around 8000-15000 hours. With time, the need to replace pump diodes or other parts can only cost you more.

Manufacturers like Precitec Laser Parts and Prima Laser Parts ensure that the machines are of good quality. So if you are ever looking for one, make sure you check them out. 

3. Fiber Lasers

Here comes the fiber laser cutting, the most popular and widely used process. Optical fibers are of a solid-state group and are quite similar to crystal lasers.

They also have a wavelength of 1.064 meters.

In comparison to CO2 laser cutting, they offer faster speed, less power consumption, and significantly reduced operational costs. 

What makes fiber laser cutting demanding is its service life. The lasers have a life of around 25,000 working hours, far more than the other two. It requires less maintenance. The replacement parts are inexpensive.

With types, it is quite clear that laser technology is a state of the art technology that requires experienced hands with advanced tools.

Different Laser Techniques

As we saw different types of lasers and laser cutting processes, there are different things that we can do with laser technology. Let us check them out. 

1. Marking

Marking is a process in which the laser melts the surface of the material and marks it. 

2. Engraving

Engraving is quite similar to marking. However, here the mark created is quite deep. Barcode creation is an example of it. 

3. Drilling

Drilling is a process that involves the creation of popping holes and dents in the material.

What does it mean for Businesses? 

The vast range of techniques and types means that laser technology is a futuristic approach. It can benefit a vast range of industries such as aerospace, automotive, electronics, semiconductors, and medical.

Even hobbyists and artists can use laser technology to create complex shapes and designs for their artistic purposes.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/a-comprehensive-guide-to-laser-cutting-technology

5 Ways to Reduce Laser Cutting Costs

No doubt that fabricators and machine shops prefer quality laser cutters for custom and high volume jobs. However, you can’t deny the fact that they are expensive despite being effective. 

Many manufacturers even think that their cost of laser cutting is unsustainable. Do you think the same?

If yes, then you must read this article. Here we have listed five ways to cut on the laser cutter cost.

1. Research thoroughly

From buying a pen to a laser cutter, we are always taught to ask questions about the product. Its peculiarities, functioning method, tips for using, and cost.

If you have decided to use a laser cutter, you need to ask questions about cutting edge, laser power, and brand. 

Consider why you need a product and what kind of work you want to accomplish with laser cutting equipment? Research everything about the equipment and then contact the retailer. 

In this stage, while communicating with the retailer, ask questions about the laser cutter. Enquire about the available features, specific functions, laser power strength, etc. Learn about the equipment’s launch, warranties and guarantees, and other terms and conditions. Knowing all this would help you make the right decision, and it would reduce unnecessary costs.

2. Use the flying cuts

Flying cuts means the laser is on when the head is moving. For other cuts, the laser turns on and off when the head stops moving. Implementing these would be beneficial for projects involving numerous holes. A no-break in between reduces the machinery time and optimizes productivity. 

For projects involving thick sheet cutting, this solution may not work that well.

Tip: Try to group your laser projects as it can reduce waste. 

3. Choose the sourcing method

Does your business rely heavily on laser cutting service providers?

Maybe, you are a jeweler and often need a laser cutting service to cut diamonds or other precious items. 

You might want to consider if having an in-house laser cutter would be right or continue outsourcing the service. 

Often, the option for in-house has a high weightage. However, the varying requirements, new materials, budget constraints, customers’ requests, and time required can affect the final decision. 

I am telling you this because sometimes the comfort of outsourcing may cost you double or triple the cost of having in-house equipment. For example, a jewelry designer realized that 44% of their average price went into laser cutting services, whereas the actual cost of the laser cut was $3995.

4. Evaluate the design

Before you activate the laser cutter, evaluate your designs. Narrow parts can add up the cost. So try to use Hypertherm spare parts and Hypertherm hpr260xd parts. 

As for design, check if there are double lines or overlapping objects. The presence of overlapping lines means that the machine would cut it twice, increasing the costs and time. 

Ensure that cutouts and designs are 1x more extensive than your materials’ thickness. Otherwise, accuracy may decrease, and the machine won’t cut it. All these may result in an additional cost for laser cutting projects. Thus, check the designs before you send it to the machine.

5. Keep up with maintenance

Many people think maintenance and repair are the same. Well, it is not. Repairing means to change/fix a part or component. Maintenance means to keep the machine in good condition by checking it on a timely basis. 

So always maintain your laser cutters. Keep a logbook for recording it. Though a no maintenance check may look like a cost-savings option at present, in the long run, it would cost you more.

Last but not least, use high-quality Hypertherm spare parts or Hypertherm hpr260xd parts. 

Final Thought

It might seem hard, but you can easily save a lot on your laser cutting equipment with these tips. Implement them and witness the changes for yourself.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/5-ways-to-reduce-laser-cutting-costs

Difference between Laser Etching and Laser Engraving

In general, laser engraving and etching are the processes of creating permanent markings on the material. They belong to the same category, i.e., laser marking. They are equally compatible with Mazak parts and Fanuc parts. However, they still differ a lot. Where laser etching can reach a depth of 0.0001 inches, laser engraving can only reach a depth of 0.005 inches. 

Let’s learn about them in depth. 

Laser Etching Process

Laser etching is a process that creates a mark by melting the surface. It’s an enhanced concept that involves laser engraving and laser annealing. To make the mark, laser beams generate a high amount of heat, which then distorts the microsurface. The markings are in white and black color. 

It is the preferable choice for permanent marking as it requires less energy from the laser beam. You can use this process for marking, such as data matrix codes, serial numbers, barcodes, and logos.

When can you use the Laser Etching Process?

• If your part is made of metal beside stainless steel.
• You need a cost-effective solution that requires a less intense laser beam.
• You need the laser process to be fast. 
• When you need to integrate the marking before the final treatment like powder coating and heat treating. 

Laser Engraving Process

In this process, the laser sends the highly localized pulse over a thin layer of sheet and creates a code. Instead of creating micro-surface like etching, the laser engraving penetrates the material, exposing the cavity to reveal the image. Here, the laser causes the material to vaporize. The typical use of this technique is to engrave serial numbers and logos. You shouldn’t use it for marking critical parts.

When can you use it?

• You need durable marks
• The material is either steel or aluminum
• You need to integrate markings before treatments like shot blasting and sandblasting.  

Why do you need Laser Etching and Laser Engraving?

There are different marking technologies like inkjet printing, dot peening, and printed labels. However, they come with their maintenance and consumable costs. Not to miss the inconsistent results of these unreliable marking systems.

Laser etching and engraving processes use high-quality parts such as Mazak parts and Fanuc parts. It reduces consumable costs and encodes the information permanently. The product can’t detach after marking. The processes involve high resolution, which means you can encode more information in less space. Laser marking technologies like Fiber and CO2 require no maintenance; pulse fibers consume very little power. 

Difference between Laser Etching and Laser Engraving

Though both are susceptible to make a permanent mark, here are the differences that distinguish them. 

• Laser etching is fast, whereas laser engraving is durable. 
• Laser etching melts the material and thus requires less energy. Laser engraving vaporizes it and requires more energy.
• Laser engraving digs holes that have better protection over abrasion. Laser etching loses it over.
• Laser etching can lift upto 80 microns, whereas laser engraving can lift upto 500 microns. 
• Laser etching only creates black and white marks. For high contrast markings, you should prefer laser engraving.
• Laser etching is a preferable option unless you require high abrasion resistance. In that case, laser engraving would be the right choice. 
• The markings of laser etching processes are usually pale, whereas engraving ensures dark marks. 

Conclusion

Choosing one is not that difficult unless you have a lot of requirements. If you don’t need a detailed and resistant work feature, you can go for laser etching. The material would matter, though. For a high resistant mark, choose laser engraving. 

This is what we think, but your final choice should be the one that meets all your conditions.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/difference-between-laser-etching-and-laser-engraving

Top 6 Benefits of Laser Engraving Machines

Laser cutting is an advanced level technology useful in many metal fabrication projects. There are many different methods that fabricators use to cut metal, but laser cutting is one of the most advanced techniques, because of their ability to make precise cuts at an unmatched speed.

So, if you too are in manufacturing and are considering using laser cutting in your next project, you might be thinking about its benefits.

Today, in this article, we decided to come up with the benefit of laser cutting machines. Let’s discuss them in brief:

1. Short lead times:

Laser cutting is known to cut metals accurately at faster speeds. When you are dealing with metals under ⅜” thick, laser cutters will cut faster. When dealing with thick materials, the cutting time length increases, but they still work quickly. Laser cutters suit well for operations of both small and large scales and can help shorten production time. To do so, it decreases the time occupied by cutting materials. With the right type of laser cutter, fabricators offer the fastest cutting speeds on the market. Additionally, use laser machines which have mitsubishi replacement parts, mazak replacement parts  as they are easy to find and replace.

Laser cutters can be very useful in helping to rapidly create prototypes. Additionally, you can decrease the cutting times, and laser fabrication increases efficiency because you can program multiple parts simultaneously.

2. Precision:

Nothing can beat laser cutters in precision. CNC routers program the cutters for complex cuts in elaborate geometric patterns, and the result is accurate cuts and shapes. A laser cutter provides clean edges and a smooth finish. They can easily burn, vaporize, or melt. Due to this, there is no extra debris, which can lead to rough cuts. This not only creates high-quality parts but even helps to reduce waste during production. Laser cutters can produce parts with a high degree of accuracy; they are a perfect choice to cut parts to fabricate aerospace parts and medical devices. It’s a tight dimensional tolerance, and quality standards are necessary. 

3. Energy:

The efficiency of laser cutters, combined with technology, causes it to use less energy than other cutting methods. Laser cutters will use about 10kW of power during the cutting process. At the same time, other cutting mechanisms use 50kW of power. The manufacturers work smarter and use less energy both as a cost-saving mechanism and environmentally friendly. They are a great way to cut down energy usage during fabrication.

4. Consistency:

Laser cutters provide precise cuts. You need to be sure that your parts and assemblies are accurate. Laser cutters programmed with CNC CAD/CAM programs. It ensures that the same cuts can repeat as many times as necessary. Because laser cutting is very precise, you can be sure that its cuts will be exactly as programmed. The result is consistency in each fabrication project. When creating multiple copies of the same products, you can be sure that each copy comes out. You can also assure that each time you use the laser cutter, it will produce the same quality product.

5. Versatility:

Multi-axis lasers allow a wide range of projects that laser cutters can complete. Laser cutters can accurately cut a wide variety of material, including metals, alloys, diamonds, plastics, woods, and glass, and even different materials at once in intricately precise shapes. Their precision and accuracy mean that the types of cuts that laser cutters can make are endless.

6. Reduced Finishing Requirements:

The laser cutter produces highly precise cuts that lead to a few necessary finishing requirements. Edges produced by laser cutters are smooth and free from burrs. The beam focuses tightly, meaning there will not be internal flaws from heat exposure. Laser cutters will produce high quality, precise cuts; quality checks will take less time. They ensure that all parts specifications are met and lead to efficient quality checks.

Conclusion:

Make sure to use the laser engraving machines to its full potential and show your creative side to the world. You can also turn into a fabricator and start your own business. Make sure to use the laser machines with Mitsubishi replacement parts, Mazak replacement parts as they are easy to find and replace.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/top-6-benefits-of-laser-engraving-machines