Laser cutting offers a number of advantages over traditional mechanical cutting methods (such as die punching or saw cutting) as well as other similar techniques, such as plasma cutting or waterjet cutting.
Many of the advantages stem from the fact that laser cutters cut with a narrow beam with a favorable wavelength and from the fact that there is a good level of energy containment in the cutting process.
Next, we’ll share why these properties create advantages over other cutting methods.
Higher Accuracy and Smaller Kerf Sizes
Accuracy - The beam from laser machines is extremely focused and only touches a small surface area on the material, meaning that they produce very accurate and focused cuts. With accuracy levels of ±0.1 mm, laser cutters are often best where a high level of precision is required.
Kerf - The narrow area of focus with a laser beam also results in smaller kerf widths compared to other methods. Kerf is the width of the area of material removed during the cutting process.
The kerf laser cutting makes is barely larger than the size of the beam. It is possible to produce kerf widths as narrow as 0.1mm with laser cutting, although kerf widths vary between 0.1mm and 1mm. The kerf thickness depends on the laser cutter being used and the material being cut.
In comparison, waterjet cutting produces a kerf width of around 0.9mm, while oxy-fuel and plasma cutting produce kerf sizes of 1.1mm and 3.8mm, respectively. To compare laser cutting to manual cutting methods, mechanical or hand saws generally produce a kerf size of about 3.175mm (10x the kerf of a laser cutter).
Having a smaller kerf size has the following advantages:
High Levels of Repeatability
Laser cutters produce complex, precision parts in a repeatable and efficient manner, and this allows manufacturers to create multiple exact copies of the same parts over large production runs or even in separate production runs.
Laser cutting machines are CNC controlled, and generally operated using complex software to optimize part path, machine speed and sheet metal utilization. As well as this, laser cutters also cut without making contact with the material they are cutting. No wear or degradation occurs at the laser cutters cutting edge, meaning that the cutting action does not vary across a production run. This compares to saw cutting, for example, where the blade may deteriorate or become misshaped during production.
This advantage applies when comparing laser cutting to mechanical cutting methods, such as saw cutting. Waterjet cutting and plasma cutting offer similar levels of repeatability as laser cutting.
Less Material Contamination in the Cut Area
Many mechanical cutting methods require cutting oils to reduce friction and otherwise aid in the cutting process. Cutting oil can, however, be tough to remove after cutting, even with the aid of processes like shot blasting. This cutting oil can hinder later processes, such as the proper adhesion of finishes or protective coatings that are applied to a part after cutting, for example.
Laser cutting does not share this drawback because there’s rarely any need to use coolants or lubricants while cutting.
Limited Post-Cut Finishing Requirements
Laser cutting produces high-quality cut edges, which reduces the need for secondary finishing. In many cases, no secondary finishing is required after laser cutting.
The accurate, clean cuts that laser cutters leave usually have fewer surface imperfections related to the cutting process, such as burrs or excess material, that need to be removed after cutting. The effect of friction and wear forces that can cause surface imperfections like warping or mechanical distortions is also often avoided.
Laser cutting is often much preferable in this respect, when compared to mechanical cutting methods, such as saw cutting, shearing or drilling.
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Removing surface imperfections and completing other finishing processes can significantly increase production costs. Where laser cutting avoids the use of these processes, both time and money can be saved.
As well as there being reduced need for finishing with laser cutting, there is also usually no need to clean laser cut parts after cutting. Again, this can be an advantage over other cutting methods.
Laser Cutting Offers More Flexibility
The flexibility of laser cutting presents itself in two folds.
The first is in its cutting versatility and in the broad range of custom designs and shapes that can be produced through laser cutting. Often laser cutting is the best thing for highly complex and intricate parts. When compared to other methods, such as sawing, CNC milling, flame cutting and even plasma cutting, laser cutting is much more adaptable.
Often laser cutting can quickly do in one cutting process what might need several alternative cutting processes. Certain part geometries or designs that are possible with laser cutting may not be possible at all with other methods.
As well as being able to perform many different types of cut, laser cutting can also be used for a range of different material types and thicknesses. One point worth noting, in this regard, is that laser cutting can be used to cut plastics and wood, whereas plasma cutting cannot.
Laser Cutting Offers the Best Sheet Utilization
Fig. 4: Laser Cutting Sheet Metal
As a combined result of the smaller kerf widths, lower levels of mechanical distortion, little to no surface imperfections and tighter tolerances, it’s possible to cut more parts from the same sheet with laser cutting.
With laser cutting, it’s possible to use as much as 94%+ of a sheet. This reduces cost and waste which translates directly to lower part costs than other cutting methods.
Fiber lasers are particularly good when it comes to sheet utilization.
Laser Cutting Provides Superior Speed
Laser cutters can reach speeds of up to inches ( cm) per minute. As such, they offer superior cutting speed compared to traditional cutting methods like wire cutting and bandsaw cutting.
Cutting with a bandsaw, for example, will take about 10 times as long as it takes with a laser cutter. Using a wire cutter may take up to 100 times the amount of time. Plasma and water jet cutting are also generally slower than laser cutting, except on very thick materials or in cases where the laser wattage is relatively low.
On top of this, the entire laser-cutting process is automated. There’s no need to halt the process to adjust the sheet metal or machinery when cutting intricate parts. All these factors increase the speed of production.
Factor Laser Cutting Waterjet Cutting Plasma Cutting Mechanical Cutting Precision/Tolerances ± 0. mm ± 0. mm ± 0.254 mm - ± 0.762 mm Thicker, but depends on process Intricate Design Capabilities Most Capable Most Capable Some not possible Many not possible No Mechanical Distortion Yes Yes No, especially with thin metal sheets No No Thermal Distortion No Yes No No Material Costs (Less Waste) Yes Yes More waste than with laser and waterjet cutting High waste levels with many methods Tooling Costs None None None Sometimes Low – Medium Volume Production X X X Yes Composite/Multi-layer Material Requires higher laser power Capable X Yes Thick Materials Not capable Capable Capable Capable Range of Suitable Materials Metals, plastic, wood, glass Metal, glass, wood Electrically conductive metals Metals, plastic, wood, glassTable 1: Comparison of Cutting Technologies: Laser, Waterjet, Plasma, and Mechanical
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