What is Laser Cutting: A Helpful Guide

Many components are manufactured for many industries using different manufacturing processes. Laser cutting is also one of the very commonly used methods for producing components where metal sheets are cut through the process of laser cutting.

If you want to use laser cutting in your upcoming project, and want to know what is laser cutting and how it works, read the guide below.

Was ist Laserschneiden?

Laser cutting is a machining process that uses a high beam of laser to cut materials. Laser is a short form for Light Amplification Stimulated Emission of Radiation. It is a very common cutting process and is used by high-volume manufacturing industries as well as small workshops.

How Does Laser Cutting Work?

The process of laser cutting works by using a beam of laser, and the entire method has various steps, each having its significance. The step-by-step working process of laser cutting is as follows:

• The process of cutting is dependent on the G-code file, which includes the instructions that will enable the machine to perform the cutting task. G-code is a set of instructions that can be read by the machine, and if the shape is more complex, CAM software is required.
• The laser beam is then generated, and every type of laser technology uses differing laser generation mediums. A photon stimulates the electron and absorbs the energy so that it can energize it. The electron decays to a low orbit and causes the emission of a photon, which creates the laser beam.
• The photons shoot in different directions and create light waves of different wavelengths.
• After amplification, the laser beam leaves the laser medium and passes through a fiber optic cable. The beam is then passed towards the sheet metal at a high intensity.
• As the focused beam reaches the material, the material evaporates and melts. The material is cut after being melted.

Types of Laser Cutting

There are various types of laser cutting processes, which are discussed in the section below.

CO2 Laser Cutting

A CO2 laser is a laser tube containing gasses like carbon dioxide, helium, and nitrogen. Nitrogen gas stores energy, which is then transmitted to carbon dioxide and helium, which help release the energy left over after the emission of photons.

The electric field excites the molecules of carbon dioxide and creates photons that bounce between two mirrors, one fully reflective and the other partially reflective. The tube also needs to maintain its efficiency by cooling and using liquid or cooling gas. CO2 lasers are highly effective for metal cutting, but they are not as effective on reflective and thermally absorptive materials.

Fiber Laser Cutting

Fiber laser cutting consists of using an optical fiber for the purpose of light amplification and doesn't have a gas discharge. It consists of emitting light through the laser diodes, which then pass through an optical fiber. It creates a light beam that is very strong and can melt stainless steel, having a thickness of 1 cm. It has a strong system of airflow and creates clean cuts.

Nd: YAG Laser Cutting

The Nd: YAG laser uses crystals of neodymium-doped yttrium aluminum garnet in the laser to create a laser beam. They can create pulsed and continuous beams of laser.

Excimer Laser Cutting

Excimer laser cutting uses an ultraviolet beam. It is suitable for cutting processes that take place in small-scale production. It is used in cutting Halbleiter, creating microelectronics, and performing eye surgery.

Direct Diode Laser Cutting

Direct diode laser cutting uses the beam of laser from the diodes directly. It doesn't have any medium of amplification and creates a very strong laser beam. It is excellently efficient at cutting components.

Methods and Techniques of Laser Cutting

The different methods and techniques of laser cutting are discussed in the section below.

Fusion Cutting

Fusion cutting is a method of laser cutting that works using the melt-and-blow technique. The laser beam, when passing through the material, melts the material, and then the blower removes the molten material from the component. It is suitable for thick material and uses inert gases.

Brennschneiden

Flame cutting uses oxygen to cut the material and carries out an exothermic oxidation reaction, which reduces the need for laser energy. The oxygen blows the material from the cut, which has melted.

Remote Cutting

Remote cutting is also known as vaporization or sublimation cutting, and it is suitable for materials that are thin and sensitive. In the process of remote cutting, no gas is used. It vaporizes the material, and it is suitable for thin materials, offering a quick cut.

Thermal Stress Fracture

Thermal stress fracture cutting is a method used to cut material by putting stress in the part. A beam of laser is used to melt a thin material layer, causing stress after cooling down to create a cut.

Stealth Dicing

Stealth dicing is a method of cutting in which the laser’s focal point is placed within the material. It creates a wafer that is expanded with a flexible membrane that creates cracks. These cracks then lead to cutting the material internally.

Vector Cutting

Vector cutting is a laser cutting process that creates a very clean line on the cut. This process involves cutting through the laser in the form of straight cuts.

Laser Rastering

Laser rastering is a method that creates an engraved cut in the material. The laser cutter burns the image as given in the instruction set, and the engraved image is created.

Common Uses of Laser Cutting

The laser cutting process has different uses, and some of these are as follows:

Sheet Metal Cutting

Laser cutting helps in cutting sheet metal with speed and precision. The creation of intricate patterns and complex designs for industries like aerospace, construction, and automobile can be used.

Engraving

CO2 lasers are used for the purpose of engraving in materials like glass, wood, acrylic, and even certain metals. It helps to create patterns for the signage or decorative items.

Laser Welding

Laser welding helps join metal parts together, and these welds are very clean and commonly required in the manufacturing and automobile sectors.

Tube Cutting

Laser cutting helps in cutting pipes and tubes with precise dimensions. Many industries require such tubes and pipes for structural applications.

Pros and Cons of Laser Cutting

Laser cutting has its fair share of pros and cons, which are discussed in the section below:

Profis

• Laser cutting leaves highly precise and accurate cuts when compared to other types of cutting processes.
• The thinner materials can be cut through laser cutting at a very fast speed.
• It is a versatile method that can be used for many applications and can cut a wide range of materials.
• It doesn't create any dust in the component and leaves behind clean cuts with no residue.
• Laser cutting is a precision-oriented method that removes a very small amount of material from the workpiece, reducing wastage.

Nachteile

• Laser cutting is expensive due to high maintenance and initial cost.
• The operator of the laser cutter needs to have safety training to operate the lasers.
• Some materials are not safe for laser cutting, and to avoid machine damage, they should be avoided.
• Laser cutting is suitable for thin materials like thin sheets of metal and not for thick blocks.

Common Laser Cutting Materials

There are different types of materials that are compatible with laser cutting, and these are as follows:

Metalle

Laser cutting is one of the most commonly used methods for cutting metals. Many components are made using laser-cut metals for different applications. The different types of metals compatible with laser cutting consist of steel, copper, Aluminium, nickel, tungsten, and brass.

Kunststoffe

Plastics create toxic fumes when heated and, hence, may be a bit tricky when it comes to cutting them with a laser. Hence, only certain types of plastics are compatible, which consist of acrylics, POM, PMMA, polyester, polycarbonate, polyethylene, mylar, Delrin, and polypropylene.

Holz

Laser cutting helps with cutting wood as well, and hence, laser engraving is carried out on wood. There are different types of wood that are suitable for laser cutting, among which plywood, hardwoods, and softwoods are used.

In addition, different types of ceramics, foam, paper, and glass products are also manufactured through laser cutting.

Which Materials Cannot Be Laser Cut?

Laser is also incompatible with some types of materials, and these are as follows:

Laminated Fiberglass: The laminated glass fiber should not be cut using laser cutting as it leads to poor cuts.

HDPE: It tends to melt upon laser cutting rather than vaporizing.

Polystyrene and Polypropylene: The foams of these materials can catch fire during the laser cutting process.

ABS: Instead of vaporizing, the ABS melts when subjected to the laser beam and also generates a toxic gas.

Polycarbonate: Polycarbonate sheets, which have a thickness of more than 1mm, can catch fire during laser cutting and even change their color.

PVC: When subjected to a laser beam, PVC causes damage to the equipment.

Applications of Laser Cutting

Laser cutting is used in many industries, and some of its applications are as follows:

Auto

In the automobile sector, the use of laser cutting helps in cutting sheet metal and creating components like suspension, exhaust systems, and frames.

Luft- und Raumfahrt

The aerospace sector needs to have precision in each of its components. Hence, laser cutters are used to create precise cuts of turbine blades and frames of aircraft.

Elektronik

Laser cutters can help make components for electronic devices with consistency, like tablets, smartphones, laptops, etc.

Architecture Applications

Laser cutting is used to create decorative cuts and engraving in many artworks and decorations.

Schlussfolgerung

Laser cutting is prevalent in many applications. Choosing the right method and right type of laser is very important for obtaining accurate and precise cuts. If you are also looking to have your components manufactured using the finest laser-cutting services, we at DEK can cater to you.

FAQs

What are the dangers of laser cutting?

The dangers associated with laser cutting consist of fire, high temperature, and burning.

What are the differences between laser cutting and CNC cutting?

CNC cutting machines cut the material using friction, but laser cutting uses laser beams.

Is laser cutting cost effective?

Laser cutting reduces wastage and is a faster process; hence, it is cost-effective for small volumes of products.

How long do laser cutters last?

The laser cutters can easily last for a time span of around 8000 to 10000 hours.

What are the alternatives to laser cutting technology?

The alternatives to laser cutting are plasma cutting, CNC machining, and water jet cutting.

How deep can a laser cutter cut?

A laser cutting machine can create a cut of a maximum of 20 mm depth.