Sheet Metal Laser Cutting Services

Fibre laser cutting is a highly efficient, precise, and super-fast method of cutting metal sheets using a laser beam. This technology has revolutionised the manufacturing industry by offering numerous advantages over traditional cutting methods such as plasma and Co2 laser cutting. However, like any other technology and methods of cutting sheet metal, fibre laser cutting also has its limitations and disadvantages.

Here we will explain some advantages and disadvantages of sheet metal cutting using a fibre optic laser cutting.

The Benefits

Precision: One of the biggest advantages of sheet metal laser cutting is its exceptional precision. Fibre laser cutting machines can achieve a high level of accuracy and precision, allowing for intricate and complex designs to be cut with ease. This precision ensures that the final product meets the specifications and results in high-quality parts and profiles.

Versatility: Fibre laser cutting is a versatile process that can be used to cut a wider range of materials and greater thickness than Co2 laser cutters, including stainless steel & aluminium as well as highly reflective material that were not suitable for Co2 laser cutters such as copper, brass, and bronze. This versatility makes it an ideal choice for various industries, such as automotive, marine, renewable energy, electronics, and architecture.

Speed: Fibre laser cutting is a process compared to traditional cutting methods. Fibre lasers are super-fast, can cut through the metal sheet quickly and efficiently, reducing production time and increasing productivity. This speed advantage is particularly beneficial for large-scale manufacturing operations and urgent client requirements and express next day cutting services.

Minimal Material Waste: Unlike cutting methods such as guillotining and shearing, fibre Laser cutting is a non-contact process, which means there is no physical contact between the cutting tool and the material being cut. This results in minimal material waste, as the laser beam only removes the necessary material. 

Complex Shapes and Designs: Fibre Laser cutting allows for the cutting of complex shapes and designs that would be difficult or impossible to achieve with traditional cutting methods such as plasma, and guillotine metalworking machines. The laser beam can follow intricate patterns and designs, enabling the production of highly detailed and customised profiles in sheet metal.

The Drawbacks

Material Limitations: While sheet metal fibre laser cutting is versatile, there are materials that are not suitable for this cutting method. For example, leather, wood, plywood, MDF, carbon fibre, cardboard, paper, plastics, textiles, acrylic and composite materials cannot be cut on a fibre laser cutting machine. Fibre lasers are designed for cutting sheet metal, with the exception of silver, which due to the highly reflective properties is not a metal suitable for this type of cutting process.

Heat Affected Zone: Laser cutting generates heat, which can result in a heat-affected zone (HAZ) around the cut edges. This HAZ may cause changes in the material properties, such as hardness and strength. The melting and subsequent cooling of the material changes the material structure. This effect is more obvious in mild/carbon steel cutting where oxygen is used as the cutting gas. The interaction of oxygen with the heated metal causes a reaction that heats the material to a greater temperature.

Blemishes and Scratches: Laser cut components will possibly need further finishing to ensure they are ‘ready for use’ or to achieve a uniform appearance. It is common for laser cut items to have blemishes/scuffs/scratches, primarily on the back face of the profile. There are two reasons for this damage to occur and both are caused by the laser cutting bed. Consisting of parallel rows of ‘pointed’ copper slats spaced 50 mm apart, when the laser beam comes into contact with a slat then splatter (Flashback) is deposited onto the reverse face of the profile. The second is caused by loading and unloading the sheet. The slats are designed in a way to minimise contact with the bottom of the sheet, thereby reducing interference with the ejected material while still offering adequate support to the sheet during cutting. 

Lead-ins/Tagging and Pips: A Lead-in is where the laser first pierces the material to start (lead in) cutting the design. The laser almost finishes the cut at this same point, but not quite, this is intentional, leaving  a very small uncut section, commonly called a tag , the tag plays a crucial role, keeping  the part and its cut-out sections in place and attached to the sheet so they do not fall into the waste collection bins beneath the laser cutting bed.  Additionally, it helps to prevent the part from shifting or tipping during the cutting process Any external or internal cut on a part, whether straight or curved, usually needs its own lead-in. When the part is removed from the sheet, the tag is ‘snapped/broken,’ leaving behind a small protrusion often called a 'pip or tag' on the cut edge(s) of the laser cut profile.

Distortion, Warping, Bowing and Flatness: Laser cut parts can experience warping or bending while being cut. The intense heat produced during the laser cutting process can cause certain areas of the material to heat up more than others. As the material cools at different speeds, it can lead to uneven contraction, causing warping, bowing and flatness issues. Additionally, the more intricate and detailed the design, the higher the likelihood of uneven expansion and contraction, which can ultimately impact the flatness of the final product.

Conclusion

Sheet metal laser cutting has numerous advantages, including precision, accuracy, versatility, speed, minimal material waste, and the ability to create complex shapes and designs and is very economical. However, it also has its limitations including some material and thickness restrictions, and the potential for a heat-affected zone. Despite these disadvantages, laser cutting is the perfect sheet metal cutting solution in the manufacturing industry due to its overall efficiency, quality, accuracy, speed, and cost effectiveness.