What Are The Pros And Cons Of Laser Cutting?

Laser cutting is one innovative technology that has significantly impacted the production and design sectors. In addition, the precise and adaptable nature of laser cutting has led to its use in many other industries, including the automotive, jewellery, and construction sectors. Before discussing the pros and downsides of this innovative technology, it is important to understand what laser cutting is and why it is so significant in the industry. Laser cutting can improve workplace productivity and precision, so join us as we explore its uses and limits.

Instructions For Using A Laser Cutter

Today's readily available laser technology has several applications, including metal fabrication. Thus, this method is employed for a wide range of cuts, from hard metals like stainless steel to softer metals like aluminium.

This technology's widespread adoption is attributed to the fact that it is now the most cost-effective and innovative cutting method. Laser technology developments have enhanced the quality and efficiency of material cutting. The three primary laser cutting techniques are now well understood. There are three types of laser cutting: melting, oxygen, and evaporation.

Fine-Tuning the Laser Cutter

These days, high-tech, user-tailored devices are used for laser cutting various materials. Adjusting the machine's settings beforehand ensures optimal performance and cost-effectiveness during cutting. Since computer numerical control (CNC) technology drives all industrial lasers, fine-tuning is a breeze. The operator of the laser cutter is the one who is responsible for regulating the forward and backward motion of the cutting head as well as the metal or other material that is being cut. In addition, the combined motion may require fine-tuning.

In common usage, X and Y represent metal and mixed motion, respectively, while Z represents laser head motion. All of these ways of doing business have their pros and cons. The laser head remains still during the cutting process, which involves moving the material being sliced. However, mixed motion involves the laser head and the material being sliced. The last kind of cutting, in which the material being cut remains still while the laser head moves, is called "moving the laser head." This is also the quickest method of cutting.

The Latest Laser Cutting Technology

Today, laser cutting is widely regarded as one of the most accessible and cost-effective technologies in the materials processing sector. With regular servicing and equipment optimisation, this technology can produce excellent outcomes. Moreover, while metal is the most common material to be cut with this technique, it is not limited to that usage.

It is most popular for cutting metal but also works well on glass, plastics, wood, etc. Like many other technological developments, laser-cutting processes are multifaceted and merit careful consideration. There are benefits to using it, but there are also some drawbacks. In some places, it will be our major cutting method, while in others, it will be one of several options. 

How does laser cutting work?

In laser cutting, a highly concentrated beam of light or radiation is utilised to heat a tiny area to a very high temperature rapidly. This causes the targeted material to melt/vaporise rapidly, allowing the spot to rapidly and precisely penetrate further into the material. 

Gas is directed at the source of the heat, where it blows the melted/vaporised substance away. Doing so exposes the cut bottom for more melting and localised cooling, allowing the cut to continue. To prevent excessive oxidation of lighter and more reactive metals, the gas assist uses nitrogen. Oxygen help, on the other hand, speeds up the cutting process for steel by locally oxidising material to aid in slag removal and lessen reattachment of melted/cut material.

There are numerous designs for laser cutters. The most common variety uses a fixed workpiece and a laser optic (mirror) that travels along the X and Y axes. On the other hand, a "fixed optic" arrangement maintains the laser head still when the workpiece is moved. Finally, a third strategy combines elements of the first two. Computer-controlled programming systems execute 2D or 2.5D G-code patterns in all three approaches, yielding completely automated, complex cutting pathways.

Pros of Using a Laser Cutter

Among the many benefits of laser cutting are:

• It's great accuracy.
• Lack of material contamination.
• Rapid processing time.
• Endless 2D complexity.
• Adaptability to a wide range of materials.
• Usefulness in various sectors.

High Precision

Extremely precise cutting is possible due to the narrow energy beam and the ability to move the material and the laser optics precisely. Even on challenging or delicate material substrates, laser cutting enables the execution of complicated designs at high feed rates.

No Material Contamination

When using a rotary cutter to process materials, it is customary to use coolants. The cut pieces may become contaminated with the coolant and require de-greasing. Grinding operations may call for the use of a coolant or lubricant. Carbide grains, left behind after the ablation of the grinding wheel, pose a risk in many finished goods. Garnet dust is also left behind when using a water cutter. There is no chance of material contamination in laser cutting because only energy and gases are used.

Rapid Pace

Laser cutting is far faster than most other production methods. For example, a 12 kW oxygen-assisted laser can cut through a 40 mm steel sheet at rates roughly 10x quicker than a bandsaw and 50-100 times faster than wire cutting.

2D Complexity is Unlimited

Since the laser's hot spot of the applied energy is so small and the G-code movement control method of positioning is so precise, it is possible to cut intricate designs. In addition, weakly-attached features can be removed from the main body without the need for any force, making the process's limitations mostly those of the materials themselves rather than the capabilities of the process itself.

Different kinds of Materials

Acrylic and other polymers, mild steel, stainless steel, Hastelloy, titanium, and tungsten are just some of the many materials that can be efficiently sliced using laser cutting, thanks to the adaptability of the technology. As technology progresses, this adaptability will only increase. Cutting carbon fibre-reinforced composites, for instance, requires a laser with a frequency matched to both the fibre and the bonding agent.

Cons of Laser Cutting

Laser cutting has some drawbacks, including thickness restrictions, toxic gases and fumes, excessive energy consumption, and high initial expenses.

Thickness Restriction for Certain Materials

The typical laser cutter operates at a power level of 6 kilowatts. They can only cut through metal as thick as 12 mm (at a rate of 10 mm/s). The largest and most powerful equipment is required to achieve the physical limitations of cutting. However, the same constraints also constrain waterjet and wire erosion cutting. These three methods all make these more in-depth cuts more quickly than would be possible otherwise.

Toxic Gases and Vapours

Indeed, cutting many metals and other materials doesn't release toxic gases, but many polymers and certain metals do. For example, when heated to high temperatures, PTFE and other fluoropolymers release phosgene gas (which is toxic to human physiology and the environment). Therefore, processing these components in a vacuum is not an option.

High Input of Energy Needed

Compared to other types of cutting instruments, laser cutting machines have a far greater energy consumption rate. For example, cutting out 40-millimetre steel plate blanks with a 3-axis CNC machine uses around one-tenth as much energy as laser cutting out the same product. If the laser cutter takes 1 minute to complete the task while the CNC takes 20 minutes, the laser cutter uses only half as much energy overall. In this respect, each component will have a unique profile, and analysing the differences might be challenging.

Initial Expenses

Laser-cutting machines have drastically varying list prices. Expenses that come up front can include:

• Machines rated at 1-3 kW that are suitable for light use with steel sheet thicknesses of up to 10 mm and moderate throughput can be purchased for as little as $2,500.
• Higher-power machines ranging from 6–10 kW start at $10,500 and can go up to $155,000 for high-capacity models from popular manufacturers. These machines are capable of deeper cut depth and faster processing.
• This is on par with the price of a basic 3-axis CNC machining centre, which can be purchased for $8,500, or a 5-axis CNC of a similar grade, which can be purchased for $24,500, with high-end models costing upwards of $265,000.

Starting a laser cutting business requires significant upfront investment in equipment and training. Using a laser cutting service like Xometry, however, is surprisingly affordable.

Methods Other Than Laser Cutting

Besides laser cutting, there are also plasma cutting, wire cutting, computer numerical control machining, and waterjet cutting.

Plasma Cutting

Plasma cutting, like electrical discharge machining (EDM), uses an arc to shred material from its base. In this case, however, the electrode is suspended in a superheated gas plasma stream, which guides the arc and expels the molten material from the incision. When it comes to cutting metal, plasma cutters and laser cutters are very similar. Plasma cutting is also suitable for heavy materials and coarse processing, such as preparing large steel components for ship and architectural projects. However, compared to laser cutting, this method is less clean and usually requires extensive post-cut cleanup to make presentable pieces.

Waterjet Cutting

Cutting with a waterjet may be done precisely on a wide variety of materials, requiring only a tiny machine. The garnet abrasive used is far tougher than the bulk of the materials handled, yet the toughest workpieces still present a difficulty. When cutting through thicker, harder materials, laser cutting outperforms waterjet. Nevertheless, Waterjet and laser cutting are comparable in that both generate high-quality cut pieces, can be used with various materials, and have a narrow kerf (width of the cut).

Computer Numerical Controlled Machining

One of the more time-honoured techniques for removing components from sheets of material is CNC machining. Precision parts may be made quickly, reliably, and with high reproducibility, making it comparable to laser cutting. However, CNC cutting takes more time and effort to set up than laser cutting. In addition to lower throughput and capacity and increased manual intervention, CNC also offers fewer benefits. However, similar quality can be achieved at a typically higher cost. When using a rotating cutting tool, greater force is applied to the material being cut, which can lead to increased local heating. CNC processing's key benefits are its adaptability to complex 3D designs and its capability to perform partial depth (rather than thorough) cuts.

Laser Cutting and Safety

Laser cutters can engrave and cut with pinpoint accuracy because of the laser's high power. However, in addition to the risk of fire, laser cutters can produce combustion byproducts that are toxic or irritating. Furthermore, the high-powered laser within the laser cutter can damage the user's eyes and skin if it escapes.

Get an "air assist" model when shopping for a laser cutter. This feature is optional but crucial for fire safety.

Best Practises for Safe Operation

• Be sure you get proper training from an experienced professional before operating a laser cutter. It would help to have a written protocol for using a laser cutter.
• Always refer to the manufacturer's instructions before operating a laser cutter.
• Maintain a diary of laser cutter usage, including user names, times, and materials sliced.
• Place a fire extinguisher on the wall close to the laser cutter, just in case.
• Fires can be avoided by routinely sweeping the laser cutter's cutting deck and internal cavity.
• Identify the materials that can be cut without risk. Hydrogen chloride gas is produced by some materials, such as PVC, and is quite harmful. 
• Never walk away from a laser cutter while it's working.
• Be wary about setting up laser cutters near any wood.
• Learn how the laser's pulse rate can be adjusted to optimise fire prevention and cutting precision.
• The cutter's laser safety features should never be disabled. This could cause the laser cutter's beam to leak.

Conclusion

Laser cutting is a cutting-edge technology that has revolutionised the manufacturing and design industries, among many others. In addition to being the most efficient and novel cutting process, laser cutting also comes in three distinct varieties: melting, oxygen, and evaporation. In order to get the most out of your laser cutter and reduce your costs, fine-tuning is a must. With regular maintenance and optimisation, cutting-edge laser technology is one of the most affordable options in the materials processing industry. Laser cutting is a multi-step procedure that involves rapidly heating a small region to extreme temperatures with a focused beam of light or radiation.

Blowing gas at the heat source removes the melted/vaporized substance. Laser cutters come in a wide variety of configurations, some of which include a stationary worktable and a reciprocating laser optic (mirror). A laser cutter's advantages include its precision, cleanliness, speed, capacity to process a broad variety of materials, adaptability, and versatility across a number of fields. Materials like acrylic, mild steel, stainless steel, Hastelloy, titanium, and tungsten are no match for the precision and speed of laser cutting. Thickness constraints, poisonous gases and fumes, high energy requirements, and high startup costs are only some of the downsides.

You can use it to effortlessly slice through tough materials without damaging delicate patterns or details. Limitations on material thickness, emissions of poisonous gases and fumes, excessive energy consumption, and high startup costs are just some of the drawbacks of laser cutting. Cutting steel plate blanks with a laser is a common practise, but it calls for a sizable initial investment in machinery and expertise. Plasma cutting, wire cutting, CNC machining, and waterjet cutting are among other options. Waterjet cutting employs a garnet abrasive to slice through thicker, harder materials, while plasma cutting uses an arc to tear material from its base.

When cutting thicker, harder materials, laser cutting is superior to waterjet. High-quality, versatile, and with a small kerf, waterjet and laser cutting share many of the same characteristics. Traditional CNC machining has less advantages but can provide comparable results at a greater price. Cutting with a laser requires special care to avoid injury to the operator, as the remnants of combustion can be toxic or irritating and cause burns if they get into the eyes or skin. You should never leave a laser cutter unattended while it's cutting, and you should also learn how to adjust the laser's pulse rate and keep a log of your usage.

Content Summary

• Laser cutting is an innovative technology with significant impact in production and design sectors.
• Laser cutting is widely used in automotive, jewellery, and construction industries.
• Laser cutting improves workplace productivity and precision.
• There are three primary laser cutting techniques: melting, oxygen, and evaporation.
• Adjusting machine settings beforehand ensures optimal performance and cost-effectiveness.
• Laser cutting allows for precise cutting on challenging or delicate materials.
• Laser cutting does not contaminate materials with coolant or lubricant.
• Laser cutting is faster than most other production methods.
• Laser cutting enables cutting of complex 2D designs.
• Laser cutting is adaptable to a wide range of materials, including metal, glass, plastics, and wood.
• Laser cutting has high precision due to the narrow energy beam and precise movement control.
• Laser cutting does not release toxic gases for many materials, but some polymers and metals do.
• Laser cutting machines have higher energy consumption compared to other cutting instruments.
• Laser cutting machines have varying upfront costs, depending on their power and capacity.
• Laser cutting has thickness restrictions for certain materials.
• Laser cutting can produce toxic gases and vapours from certain materials.
• Laser cutting requires significant upfront investment in equipment and training.
• Besides laser cutting, other cutting methods include plasma cutting, wire cutting, CNC machining, and waterjet cutting.
• Plasma cutting is suitable for heavy materials and coarse processing but requires post-cut cleanup.
• Waterjet cutting can be done precisely on various materials, but laser cutting outperforms it for thicker, harder materials.
• CNC machining offers precise and reproducible results but requires more time and effort to set up compared to laser cutting.
• Laser cutters can produce combustion byproducts that are toxic or irritating.
• Proper training and adherence to safety protocols are necessary for safe operation of laser cutters.
• Maintaining a clean cutting deck and internal cavity helps prevent fires in laser cutters.
• Some materials, such as PVC, can produce harmful gases when cut with a laser.
• It is important to stay present and cautious when operating a laser cutter.
• Laser cutters should not be set up near wood to prevent fire hazards.
• Understanding the laser's pulse rate helps optimize fire prevention and cutting precision.
• The laser cutter's safety features should never be disabled to prevent beam leakage.
• Using a laser cutting service can be an affordable alternative to starting a laser cutting business.