5 Laser Cutting Maintenance Tips

If you use a machine vigorously, you know its consequences. It would wear out sooner than expected. The productivity and efficiency would decrease too. 

This principle applies to every machine that we use, including laser cutting machines. If we maintain it properly, we can enhance the longevity of the laser cutters. Though the machines often come with service contracts for a given period, ensuring proper use and brand-specific spare parts like Bystronic parts and Fanuc spare parts is smart.  

However, if we look at the machines only when they malfunction or are broken, it will increase the cost and efforts. Therefore, it is crucial for metal fabricators to maintain their laser machines or it might affect their work and quality. If maintained properly, it can help you save a great deal. Here are the maintenance tips for maintaining your laser machine’s competency and throughput.   

1. Keep the air sources clean

Laser cutting machines use different types of gases like oxygen, nitrogen, or shop air to cut metals. Most of them use shop air as it has the fastest processing speed. It helps cut various metals like stainless steel, aluminum sheets, metal sheets, etc. So, for gases to cut the metal with perfection, ensure that the compressor gas is not impure instead moisture-free. Keep the lines clean and maintain the air pressure and air filtration properly. Do this regularly as the compressor source and lines affect the machine’s performance, productivity, and working life span. 

2. Inspect the parts regularly

The simplest tip to prolong a laser cutting machine’s life is to inspect all the parts on a daily and weekly basis. Check if the pressure of working gas and cutting gas is enough or not. If not, replace it immediately. Check whether the limiting switches of each axis are sensitive. The indicator lights are damaged, whether there are any leakages, etc. See which part needs replacement and replace it with branded parts.

3. Review your chiller performance constantly

Like plasma cutting, fiber laser cutting uses heat to cut the metal. So, you should ensure that the equipment remains cool and doesn’t overheat. Clean the condenser coils, filters, and fans so that they perform well. If there is debris in the filters or fans, they won’t cool the machine. In fact, the discrepancy in the temperature could lead to poor performance. 

Many chillers require additives and chemicals, so maintain them at regular intervals. 

4. Ensure regulated power supply

After one month of continuous power supply, cut off the main supply and check all the electric connections, tighten the terminals, especially the main circuit. 

Along with this, check the elasticity of the slider carbon brush, blow out the toner, and dust on the components using dry compressed air.

5. Inspect the gas delivery

Laser machines use gas to vaporize through the material. The contaminated gases affect the cut and result in poor quality. If you want a smooth cut, make sure that the gas is pure and clean. For this, inspect gases whenever possible. See if they are free of debris. Look if filters are doing their job properly. Replace the gas bottle every time you notice a leak, as it would affect the overall performance. Also, they are a safety hazard to workers working with the device. Hence, whenever you see a leak, turn off the device and then use a soapy connection rag to rub the connection line. Address it as soon as you notice a leak. Any delays will affect your performance, and even your safety will be at risk.

Conclusion

Check your laser cutting machine and parts regularly. If you find any fault or look like a part has failed or is not working properly, replace it immediately. Follow the tips mentioned above for better maintenance. Also, keep your machines clean and track every activity. Lastly, use Bystronic parts or Fanuc spare parts for replacement.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/5-laser-cutting-maintenance-tips

5 Steps to Modernize your Old Press Brake

Just like other press brake owners, you might be wondering what to do with your old press brakes. You might be caught in between selling the old and buying a new press brake. Well, if you’re planning on a new one, I would suggest going for the Amada press brake for sale. But let me tell you that replacing old with new can cost you thousands of dollars. Up of that, you might have to deal with logistics overhead.

A cost-effective solution would be to increase your existing machine’s productivity by retrofitting. In case, if you need to replace parts, you can go for prima spare parts.

While retrofitting, knowing about the type of retrofits and the ones suitable for your machine would be better. It will help you decide whether upgrading the machine is worth it or not.

You can follow these steps to assess the condition of your press brakes.

1. Evaluate the Condition of the Machine

First, identify the condition of hydraulic, mechanical, and electrical components of the machine. While doing so, focus on – RAM, pedestal control, back gauge control, and press brake control. See if your RAM is accurate, consistent, and level on both sides. If they are producing proper results, you can go with a retrofit. Also, check the bending method.

Next, check whether the foot pedestal is working or not. If it is, you can avoid replacement. Also, check if your back gauge needs replacement or reusing would work. Lastly, see if your press brake can work manually, as basic retrofit often works with it.

2. Learn About your Machine

Consider the type of machine you’re working with. If your machine is a mechanical-style press brake, you can add a standalone CNC back gauge system, though ram programmability won’t work.

Rocker-style hydraulic press brake can be retrofitted with a programmable position and control interface. Synchro-style hydraulic brakes often focus on libraries and simulations. So, learn about your machine and then consider retrofitting.

3. Identify the Pain Points

Assess your challenges by asking questions like:

• Which method would be suitable – back gauging or front gauging?
• Are you making frequent changes to the tool? Are you changing die heights often? If so, you can adjust your surface’s height to accommodate the new tool by incorporating the R axis.
• Do you often adjust the angle and depth of the ram manually? If so, adding a ram axis or y-axis would help increase productivity.  
• Do you handle the same parts multiple times and adjust the gauge often? Use the X-axis, Y-axis, R-axis, Z1 axis, and Z2 axis to increase operator productivity. 
• Are operators capable of offline programming? A few retrofits offer offline programming, so operators must be well-versed with programming and provided essential training.  

Evaluate these and jump onto the next step.

4. Determine an Approach

Retrofit companies need to know about your press brake application in order to provide a proper solution. They will ask questions like the length of the press brake. Whether you’re bending little gauge sheet metal or heavy plates. Are single operators enough to support the sheets?

So, determine the approaches you would like to take. For this, keep questioning – How much job storage do I need? Should I add the components’ programmability? Do I need a full tool library? Do I need networking? Will I import DXF, AutoCAD, SolidWorks?

Answering these questions will assist you in determining the retrofit approach.

5. Implement Your Solution

If your press brake is working properly and still you want to increase your bending process’s productivity, you can go for one of three options.

• Leave the machine and limp it for as long as possible.
• Purchase a new multi-axis press brake. (You can choose Amada press brake for sale.)
• Retrofit the whole machine or some parts. (For spare parts, refer to prima spare parts.)

Lastly, you can take the help of an experienced supplier specializing in metal forming and fabrication machinery. 

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/5-steps-to-modernize-your-old-press-brake

4 Tips to Begin your Fabrication Project

Fabrication projects like railroad tracks, power plant facilities require heavy metal cutting. So, fabricators opt for laser technology as it provides precise, accurate, and clear cuts. Also, it has an unmatched speed compared to other cutting technologies available in the market. 

In addition, what makes laser technology different is its adaptable nature. You can adjust it according to your project requirements – resolution, sharpness, depth, and whatnot. In addition to this, brand parts like Hypertherm PowerMax 45xp fine cut consumables and Hypertherm HPR 130 consumables enhance efficiency.

Here are the other things that help you improve your laser cutting for fabrication projects. 

1. Consider Material Thickness and Type

When you plan your next fabrication project, choose the material type and thickness. Every material has different thicknesses and properties. For instance, a thin metal would burn faster than a thick metal. Moreover, it won’t take lasers long to cut through the thin material. So, make sure to check the type of metal you want to use. 

After all, you’re using laser technology for its quality and speed. And choosing the perfect material or working on finding the optimal thickness of the material can considerably cut laser costs. Imagine you cut a heavy metal, and the laser technology is not compatible with it. It may wear out the consumables. 

Finding it won’t be easy if you have a complex project. However, you must consider it, or you may end up with average results.

2. Simplify the Design Elements

Try to implement minimal designs that would reduce the laser cutting usage or time. Because when you use laser cutting, every action counts. You pay for every movement the laser cutter makes. Be it cutting, engraving, or passing between cuts, your consumables and parts wear out with usage. Also, the less time the laser takes to cut, the less it would cost. 

So, keep your designs simple. Tracing minute details will take up a lot of time rather than large designs. For instance, cutting a straight line will take less time than a circle. 

3. Add Complimentary Services

Having a fabrication company that can help you build a main enclosure part or custom part is beneficial. However, look for a company that also provides services like power coating, spot welding, finishing metals, and other techniques that turn a planned component into a finished project. 

If you’re thinking about contracting low bidders for different parts of the job, then don’t. No matter how cheap the services are, it would add up the logistics of working with different companies. Besides, managing work could be challenging. It may create over-head and even increase costly mistakes.

So, hire a qualified vendor that provides complementary services.

4. Find the Appropriate Partner 

To accomplish projects successfully, you need advanced technology like laser cutting. But for quality products, having a skilled vendor is crucial. Here are the questions you must ask:

• Does it have technical capabilities?

Fabrication and laser cutting processes need accuracy, detailed inspections. So, make sure the team can conduct tests and offer feedback.

• Is it easy to work with a particular company? 

To finish projects on time, you need a company that will provide better services and speeds up production. It can be sending designs electronically or communicating on time. 

• Does the company have a stellar record? 

Look for a company that has a record of quality services and on-time delivery. A reputed company can help you manage your supply chains effectively. So, while partnering, check their clients’ testimonials, reviews, ratings, and work portfolio. 

Overall, these three questions will give you an impression of the company you plan to partner with.

Conclusion

Follow these four tips. It will help you get the best of laser cutting for your fabrication project. Also, for consumables prefer Hypertherm PowerMax 45xp fine cut consumables and Hypertherm HPR 130 consumables.

Source: https://altparts.mystrikingly.com/blog/4-tips-to-begin-your-fabrication-project

4 Tips to Maximize your Laser Engraving Production

The good thing about laser cutting and engraving is the speed at which they can etch a pattern or carve even an intrinsic design. However, that’s not enough to boost production. Laser operators often need to look for ways to maximize their productivity. Are you, too, looking for ways to use lasers efficiently?

If so, use Trumpf Parts and Bystronic Spare Parts for laser consumables. They are durable and provide better quality than other brands. 

The other tips that ensure using laser machine to its highest potential are:

1. Engrave Multiple Items in One Go

If you want to boost your production, engrave multiple products in one. It reduces the processing time, efforts, and even cost to a certain extent. For instance, you have to engrave plaques or courses with similar designs. So, there you can print multiple at one instead of designing one at a time. It will help you save your time by 37 percent, says a study. 

However, the number of items you can design depends on your graphic table size. Therefore, make sure that your paper size of the graphic design program meets the highest table size. By doing so, you can print maximum items at once. You can use a jig to space the items so that they don’t mix up while engraving. 

2. Adjust Resolution

Image resolution is important in engraving. The higher the resolution, the better would be the image. But higher the DPI, the more time it would take to engrave. DPI refers to dots per inch, and higher DPI means the engraving dots will be closer. It would result in a higher detailed image. However, it would take more time. 

If you want to engrave in a shorter time, you can go for a low-resolution image. It would save your time by around 33%. You can also offset your resolution with dithering patterns. Dithering patterns are visual dot patterns that you can see in lower DPI. Therefore, to achieve target results adjust resolution and DPI with dithering patterns. You can engrave your design in less time. 

3. Use Color Mapping

Color mapping further helps save time. Let’s say your design consists of three columns with 30 names in each. The laser machine would consider it as a whole instead of separate columns. It would pass through the white space and engrave the names in one color. 

So, to avoid this, you can use color mapping. It would enable you to skip the white spaces and assign different colors to columns, along with engraving order. With this process, your laser would consider columns as different and engrave accordingly. It would travel through the white space only when it has to switch to the next column. The color mapping approach can save you 47% more than others. 

4. Pre-Engrave Items

Customization is popular. Many businesses are adopting it to enhance the customer experience. But for your laser engraving business, it can be inefficient. If you have to engrave the same designs repetitively, it can increase the production time, resulting in inefficiency. However, you can curb it by pre-engraving the inventory before single orders come in. For example, you can pre-design a batch of keychains or cutting boards. When an order comes in, you can add a custom quote or saying according to customers and pass it on. With a little change, you can avoid bottlenecks in day-to-day orders. Also, the small change would take less time than engraving the entire design.

What’s More?

Use center engraving to set custom jobs on items. Using a job manager to streamline the laser workflow is also a great idea to boost productivity. In addition to these, make sure to add high-quality branded parts like Trumpf parts and Bystronic spare parts. After all, maintaining consumables is also a trick to increase laser efficiency.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/4-tips-to-maximize-your-laser-engraving-production

How Laser Cutting Benefits your Business

To get a cut above average, you must first know its detailing. Whether the laser cutting machine is suitable for your product or not. Only when you know the right time to use the latest technology and equipment can improve your product/service quality.

For that, you need to learn about different laser cutting machines, which brand spare parts you should use (like Mazak used parts or Fanuc parts), and so on. 

The most important thing you need to identify is the advantage this technology provides.

Let's see what they are:

1. Versatility

What's the first thing you notice about cutting tools?

It's usually how you can use them from an economy, mass production,, and components perspective. 

Talking about laser cutting, it's highly versatile. Not more people appreciate it, but it's a fact. It's a cost-effective solution for projects that require precision and intricacy.

It's a go-to solution for all metal cutting work.  

Be it aluminum, stainless steel, or titanium, laser cutting can perfectly finish different sizes. You can also apply them to cut zinc and iron.

No matter how hard the material is, it can provide high-quality results. 

2. Reliability

Manual tools and cutting methods rely on well-maintained equipment. They use the sharp cutting blade, but the blade can become blunt, slow, or smooth as the process continues. This may affect the result. There might be variance in edges, or the cutting may not be exact. 

The variances can be minute, naked to the human eye. However, they can make a significant change, mainly if the components are for robotics or automation lines. 

Laser cutting ensures 100% consistency. It ensures that there won't be a difference or distortion of even 0.1mm. 

You can rely on it because it doesn't rely on sharpened blades or oiled mechanisms. Also, there are no maintenance issues. You can directly replace the parts with branded ones, like Fanuc parts.

3. Accuracy

It's another advantage of using laser cutting technology. 

Manual tools rely on varying degrees based on the dexterity of the operator. Even a skilled one would make marginal errors such as a hairline scratch. 

Laser cutting uses digital technology. It's not prone to variations; instead, it offers a high degree of accuracy. 

For example, you want to cut material to create grooves without passing the blade all through the material. The ratio between engraving and the material edge could be fine. For manual tools, it might not be easy. But laser cutting can make that cut with attuned dimensions. 

With laser cutting technology, you can cut minus plus 0.1mm, accurately.

4. Waste and Time Management

Unlike other cutting methods and tools, laser cutting offers a safe environment and reduced waste management.

The goal of this technology is to get results with minimum waste. It means you can get your components or products ready with fewer errors. It also means that you can get more done in less time. As there's no waste, the time spent on clearing the surface is reduced. Next, you can acquire the results in one or two go. 

It's not like the manual tools. You need to move your item to different machines and position them in different angles and directions to get desired results. 

Laser cutting streamlines the process and makes it smooth. Besides, reduced waste management can further help you save costs.

5. Speed

And the primary advantage is it's fast. 

Not only for mass production. If you want to cut a bespoke item, you can take the laser cutting machine, program it, and within minutes, you can operate.

Even if you have a large consignment, you can get it done on time. Laser cutting can cut through the time you would otherwise require to set up a project or a machine. 

Time is also not a challenge. You can use laser cutting technology 24*7. 

Also, you can take repeat orders and fulfill them without re-setting up or adjusting the parameters.

That's how laser cutting technology is.

There are a lot of advantages to it. If you don't go for it today, you may regret it later.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-laser-cutting-benefits-your-business

Benefits of Using CAD-CAM CNC Control Software

The manufacturing industry has a long history of evolution. From products to tools and the working, everything has advanced. Like, we have CNC to help us carry out various activities effortlessly. The availability of Bystronic parts and Fanuc parts online to ensure the proper working of CNC, etc. 

CNC has become so common that it's rare to see industries not using them. 

Besides, adding CAD-CAM to CNC simplifies tasks and gets them done on time. It is way better than all the manual alternatives available today.

Here are the advantages of including CAD-CAM in your CNC toolkit.

1. Programming Potential

If you add CAD-CAM to your CNC toolkit, you can take on even the most challenging jobs. For instance, 3 axis machining jobs. It can help you create and manage toolpaths for jobs like molds, which are impossible to calculate manually or even via canned machine cycles. The CAD-CAM software will automate the entire process. 

2. Control over Job Programming

Modern CAD-CAM software has CAD Tree functionality that allows job tracking. You can view all the commands and processes from beginning to end.

With it, you will have full control over processing -  stock, work coordinates, material, tooling, operations, and output of NC programs. You can also save and load machining templates and copy and paste operations. Other benefits include reordering the job sequence, associating the toolpath to auto-update all the paths after the edit, etc.

With these capabilities, you can get the work done faster. 

3. Accessible by Clients

With CAD-CAM, you can receive models faster than before. You can open the file, set the toolpath, and directly perform simulations. These simulations can then help you identify the processes and plan a quote, such as calculating cycle times. 

You can deliver the products faster and at an affordable price than before. This software would allow you to design, manage projects, test, simulate, and deliver more quickly. 

4. No Guesswork

Using CAD-CAM maximizes the programming efficiency. It removes the guesswork by making operators follow the steps in creating machine toolpaths. It ensures that the operator has set cutting depths, selected tools, chose toolpath style, managed lead-ins and outs, set compensation settings, and other essentials. 

It allows programmers to be faster and handle the operations error-free even in case of high complexity. 

5. High Speed

It provides high-speed machine toolpaths that reduce cycle time and ensures less wear and tear. Instead, it improves the quality of cutting by eliminating the traditional toolpaths' stop and go actions. 

Its circular motion cutting makes the engagement with the material constant, deep, giving a sharp cut. Overall, it can improve productivity by 50 percent. 

6. Less Wastage

CAD-CAM provides simulation that helps inspect processes and catch gouges and collisions before moving to the CNC machine. It alone helps eliminate costly mistakes and waste. 

Simulations provide complete detail of the process. It helps visualize the process, such as cutting a metal sheet before the actual procedure. 

7. Simple and Cost-Effective

Creating NC programs via 4 and 5 axis machining can be difficult. But CAD-CAM makes it easier. It provides a toolpath and special post-processing to index the 4th axis. It also allows operators to customize the posts for 4 and 5 axis machines. 

You can also simulate the full 4 and 5 axes to inspect the machines before the NC program reaches the machines. 

8. Seamless Integration

You can integrate CAM machining modules into your CAD software as a plugin. This would allow you to create machining for the part, simulate, and create NC programs. The best part is that you won't have to re-learn the entire CAD-CAM system. Besides, you would be able to provide better service and programming facilities. With basic training, you can start using the tool. 

To Conclude

These advantages are enough to justify the importance of having CAD-CAM with your CNC toolkit. It will help you stay productive, competitive, and profitable. 

Meanwhile, check out the Bystronic parts for CNC.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/benefits-of-using-cad-cam-cnc-control-software

C02 Laser: Everything You Need to Know

If we go back to laser cutters' history, we would see C02 lasers on the top. And if you look at the current trends, Co2 still is one of the most useful. The technology that Kumar Patel invented in 1964 is still one of the finest laser cutting/engraving machines.

And no doubt, you can get Trumpf laser parts for the same. Bystronic also provides Bystronic laser consumables for the Co2 lasers. 

It provides high power, precision, and consistency. The sole reason why many businesses use Co2 lasers for personalization. 

Their engravers and cutters are so precise that they can create any design on any material. It doesn't matter if it's wood, metal, plastic, or paper.

How does a Co2 Laser Works?

In Co2 laser cutters, the light is produced when electricity runs through a glass-filled tube. There are mirrors on both ends of the tube. One is reflective, and the other allows light to pass through it. These mirrors help laser beams to cut. The gas in the tube consists of helium, carbon dioxide, hydrogen, and nitrogen. 

The nitrogen molecules in the tube get charged. They start producing high-energy vibrations that excite Co2 molecules. And then comes a stage of population inversion where nitrogen has to release the energy. It then comes in contact with cold helium particles and releases energy in the form of photons that produce a beam of light. 

The released light is more potent than normal light because of the mirrors. So, the mirrors reflect the light and cause waves to build in intensity. The light passes through the partially reflective mirror only when it's bright enough. 

Since it's infrared, it has a high wavelength and can cut any material. The intensity of the light vaporizes the material, thereby leaving a smooth touch. 

Depending on the material you want to engrave or cut, you can decrease the power and speed.

Co2 Laser Specifications: Lenses, Lifetime, and Spare Parts

Lenses

Just like the different power capacities of Co2, there are different types of lenses available for Co2. Based on their focal length, their purpose differs. Let's check them out. 

1. Lens 1.5"

To engrave small letters or details, these lens resolutions are highly recommended. They produce a laser beam between 0.0762 and 0.1651mm. They are suitable for materials with a thickness of less than 1.8mm.

2. Lens 2"

These are the standard lenses available in most lasers. They produce a beam between 0.1 and 0.18mm. They are best to cut or engrave materials with a thickness between 300 and 600 dpi.

3. Lens 4"

They produce a more focused cut at a vertical distance. Experts highly recommend these lenses for engraving and cutting thick material.

Lifetime

The lifetime of your laser lens highly depends on its use and handling. Maintenance is another factor that defines its lifetime. Keeping this aside, the quality of the consumables and parts also affects its durability.

For some lenses, the approx durability is around 6 to 9 months. So before you buy one, discuss it with your provider.

Spare Parts

Lasers of any type highly depend on their consumables and parts. So when you replace the parts, make sure they are of top brands. We would recommend going with Trumpf laser parts. For consumables, Bystronic laser consumables. 

Also, check out other brands such as Hypertherm, Fanuc, Mazak, etc.

Uses of Co2 Lasers

We already saw that they are the best option for personalization and high precision cutting. Besides this, you can also use them for welding or in the additive manufacturing process of selective laser sintering.

Co2 lasers are also useful in the medical field. Many surgical procedures utilize Co2 lasers as water could easily absorb the high frequency of light and make tissues. 

Laser surgeries and skin resurfacing also make use of Co2 lasers. They are also used to treat skin conditions such as hirsuties papillaris genitalis by removing bumps. 

Other branches such as dentistry, gynecology also use these lasers.

Artists providing custom wooden engraving designs use it for personalization.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/c02-laser-everything-you-need-to-know