Sheet Metal Laser Cutting: To Cut Custom Sheet Metal Parts

In industries, subtractive manufacturing techniques are commonly employed for part manufacture. The crucial production process of sheet metal laser cutting is a prime example of such a method.

In order to burn, evaporate, or melt materials and ultimately achieve desired results, the procedure focuses the laser beam on the surface of the substance. It simplifies the process of producing components with fine details since it is exact and accurate.

This is a thorough guide that contains all the facts you might need to know about laser cutting before attempting it for your upcoming manufacturing project.

What is Sheet Metal Laser Cutting?

Sheet metal laser cutting is a prominent method in sheet metal fabrication, which is widely utilized in industrial manufacturing. It involves the use of a high-power laser beam to precisely cut thin and flat metal sheets. The process relies on advanced optics and computer numerical control (CNC) technology, ensuring exceptional accuracy in producing laser-cut components.

The history of sheet metal laser cutting dates back more than 60 years, with the first attempts to cut metal sheets using lasers occurring around 1960. By 1964, CO2 lasers were already employed to manufacture intricate details, including welding clock springs. The automation and superior precision offered by laser cutting compared to other cutting methods made it highly favored for delicate manufacturing and large-scale production.

Fiber lasers were initially developed in the 1960s but did not become commercially available until the late 1980s. The 1990s marked a significant period in laser technology, witnessing the emergence of numerous high-power lasers such as solid-state lasers, which greatly enhanced efficiency and productivity. As the early 2000s arrived, laser cutting services had gained widespread acceptance as a manufacturing technique, finding application in various industries, including automotive and aerospace.

Types of Lasers For Sheet Metal Cutting

There are three primary types of lasers used for sheet metal cutting in industrial manufacturing, each with its distinct characteristics. Here is a comprehensive overview of these laser cutters:

Fiber Lasers

Fiber lasers are highly powerful and precise cutting machines. They belong to the category of solid-state lasers and utilize seed lasers to amplify the beam through specialized glass fibers. Fiber lasers are effective for cutting various materials such as metals, alloys, glass, plastics, and even wood. In addition to cutting, they are also suitable for metal engraving and annealing. Fiber lasers have a longer service life, typically exceeding 25,000 hours, and require minimal maintenance. They produce strong and stable beams, although their kerfs (width of the cut) may be wider than other lasers. Fiber lasers are most suitable for materials with thicknesses of less than 20 mm.

CO₂ Lasers

CO₂ lasers generate a beam of light by passing electricity through a gas-filled tube, primarily containing a mixture of carbon dioxide and inert gases like helium and nitrogen. However, they are less powerful compared to fiber lasers. CO₂ laser machines are primarily used for cutting non-metal materials such as wood, acrylic, and plastics. In some cases, they can also be utilized for sheet metal cutting, particularly with thin sheets of aluminum and certain non-ferrous metals. It’s worth noting that there are significant differences between fiber lasers and CO₂ lasers in terms of their capabilities.

Crystal Lasers

Crystal lasers are available in two forms: Nd:YAG (neodymium-doped yttrium aluminum garnet) and Me:YVO (neodymium-doped yttrium ortho-vanadate, YVO4) crystals. Both types are high-power cutting devices, although they tend to be more expensive and have a shorter lifespan compared to fiber lasers, typically ranging from 8,000 to 15,000 hours. Crystal lasers are suitable for cutting coated and uncoated metals, non-metal materials, plastics, and even ceramics under specific circumstances.

It’s important to select the appropriate laser cutter based on the specific requirements of the materials being cut, desired precision, and thickness of the sheets.

Sheet Metal Laser Cutting Processes

There are three main processes involved in sheet metal laser cutting, each with its distinct characteristics. Here is a comprehensive overview of these cutting methods:

Laser Beam Fusion Cutting

Fusion cutting employs an inert cutting gas, such as nitrogen or argon, to expel the molten material from the cutting torch. By utilizing an inert gas, oxidation at the cutting edge is prevented without interfering with the process. This method is suitable for cutting flat and thin sheets, particularly in cases where the material needs to meet high visual standards and requires minimal post-processing. Fusion cutting provides precise results with clean edges.

Laser Beam Flame Cutting

Flame cutting utilizes oxygen gas to expel the molten material. This process involves an exothermic reaction that increases the overall energy input. It is well-suited for cutting mild steel and various other types of sheet metals, as well as fusible materials like ceramics. Flame cutting is effective for thicker sheets and can achieve rapid cutting speeds.

Laser Beam Sublimation Cutting

Sublimation cutting involves using a laser to evaporate parts of a material with minimal melting. Similar to fusion cutting, inert gases like nitrogen, helium, or argon are used as the cutting gas, ensuring that the cutting edges remain free from oxidation. Although sublimation cutting may be slower compared to other methods, it delivers superior edge quality, making it ideal for high-precision cutting requirements.

The choice of the cutting process depends on factors such as the type and thickness of the sheet metal, desired edge quality, speed requirements, and specific material properties.

Pros of Sheet Metal Laser Cutting

Sheet metal laser cutting offers several significant advantages as a manufacturing technique. Here are five key benefits:

High Precision Cuts

Laser cutting fabrication provides exceptionally precise cuts. The laser beam melts and evaporates materials with unparalleled accuracy, surpassing the precision achieved by many other cutting methods. While traditional die cutting tools may have tolerances of around 1 to 3 mm, laser cutters can achieve accuracy as low as 0.003 mm, ensuring intricate and precise cuts.

High Sheet Utilization

Laser cutters minimize material wastage, allowing for the efficient use of sheet metal. The technology maximizes the number of usable parts obtained from a metal sheet, reducing the need for excess material. This means that manufacturers can purchase the exact amount of sheet metal required for a project, resulting in cost savings and reduced waste.

Versatile Cutting Capabilities

Laser cutting operations are highly versatile and flexible. A single laser cutter can perform various cutting tasks, including simple cuts, complex designs with intricate details, markings, drilling, and even engravings. This eliminates the need to constantly change or replace tooling during the manufacturing process, increasing efficiency and reducing downtime.

Low Power Consumption

Compared to other cutting machines, laser cutters have lower power utilization. They do not require the movement of multiple parts, enabling them to effectively cut materials while consuming less energy. While some procedures may require up to five times more energy, laser cutters can operate efficiently with as little as 10 kW of power.

Minimal or No Damage

Contrary to concerns about heat exposure causing warping, distortion, or damage to parts, laser cutting minimizes these issues. The heat-affected zone in laser cutting is minimal, ensuring that the tolerance and integrity of fabricated components remain unaffected. This means that the final parts maintain their desired features without compromising quality.

Cons of Sheet Metal Laser Cutting

While sheet metal laser cutting offers numerous advantages, it also has a few drawbacks. Let’s explore these limitations:

Requirement for Skilled Operators

To fully harness the capabilities of laser cutters, it is often necessary to employ a specialist operator. These machines require skilled individuals who can effectively set up and operate them. A knowledgeable operator can quickly identify and address any faults or issues that may arise during the fabrication process, ensuring smooth production and maintaining the machine’s integrity.

Limitations on Metal Thickness

While laser cutting is suitable for a wide range of materials, including metal sheets, it is not the optimal choice for cutting thick metals. Typical laser cutters are better suited for thinner materials. For example, they can efficiently cut aluminum sheets up to a maximum thickness of around 15 mm and steel sheets up to approximately 6 mm. When dealing with thicker metals, alternative cutting methods may be more appropriate.

Emission of Harmful Gases

During the laser cutting process, harmful fumes and gases are emitted, especially when cutting certain materials like plastics. It is crucial to operate laser cutters in a well-ventilated environment or under proper extraction systems to ensure the safety of operators and maintain air quality in the workspace. Adequate ventilation or the use of exhaust systems is necessary to mitigate the risks associated with inhaling these potentially hazardous gases.

High Initial Investment

One significant disadvantage of laser cutting is the high initial investment required to acquire a top-quality laser cutter. The cost of a typical laser cutter can be around $3000 or more, which is often higher compared to alternative cutting technologies like waterjet or plasma cutters. This initial investment can pose a challenge, particularly for small businesses or individuals looking to offer laser cutting services.

It’s important to consider these disadvantages alongside the benefits of sheet metal laser cutting to determine the most suitable cutting method for specific applications and budgetary considerations.

Design Tips for Sheet Metal Laser Cutting Parts

To ensure effective and efficient use of sheet metal laser cutting services for your parts, it is essential to follow these design tips:

Consider Metal Thickness

Take into account the thickness of the metal when designing for laser cutting. The laser’s ability to penetrate and cut the material depends on its power, which is affected by thickness. Thicker materials may require higher laser power, but there may be limitations to how thick a laser can effectively cut.

Account for Kerf

Be mindful of the kerf, which is the material that evaporates when the laser beam interacts with the cutting material. The kerf is a result of the laser beam’s thickness and is present in various subtractive machining processes, including laser cutting. Consider the kerf during the design stage to ensure accurate dimensions and proper fit of the final parts.

Choose the Right Material

Select the appropriate material based on the desired properties of the end product. Different materials have distinct characteristics in terms of rigidity, translucency, flexibility, and more. Consider the specific requirements of your project and choose the material that best meets those needs. Sheet metal laser cutting services typically offer a range of options, including sheet metal, plastics, and paper.

Pay Attention to Spacing

Spacing plays a crucial role in laser cutting to minimize errors and achieve the best possible results. Maintain a minimum spacing between features that is equal to the material thickness. For example, in sheet metal laser cutting, if the sheet metal is 2 mm thick, ensure a spacing of 2 mm between two paths or features. Proper spacing is especially important when working with intricate laser cut sheet metal designs.

Convert Text into Anchor Points and Curves

If you need to incorporate text into your design, it is recommended to convert the text into anchor points and curves. Ensure sufficient spacing between letters and enlarge the text for smoother cutting and optimal legibility. Close proximity of letters may cause overlap, resulting in an illegible final inscription.

By following these design tips, you can optimize your sheet metal laser cutting process, reduce errors, and potentially lower sheet metal fabrication costs.

Laser Cutting Machine Or Laser Cutting Service?

When considering whether to invest in a laser cutting machine or opt for a sheet metal laser cutting service, there are several factors to weigh.

Laser cutting services are essential for a wide range of manufacturing operations, from small equipment fabrications to large-scale industries like aerospace and automotive. Laser cutting is a highly efficient and effective technique suitable for various materials.

For small-scale manufacturing companies, choosing a sheet metal laser cutting service can be a smart decision. It allows them to save costs while still delivering quality to their customers. By outsourcing the sheet metal laser cutting process, these companies can avoid the upfront investment and ongoing expenses associated with purchasing and maintaining a laser cutting machine.

However, if the financial resources are available, investing in a laser cutting machine can be highly profitable. Owning a laser cutting machine offers numerous advantages, including greater control over production schedules, faster turnaround times, and the ability to handle a broader range of projects in-house. It also eliminates the need to rely on external service providers, providing more flexibility and autonomy in manufacturing processes.

Ultimately, the choice between investing in a laser cutting machine or opting for a sheet metal laser cutting service depends on the specific circumstances and priorities of the manufacturer. Consider factors such as budget, production volume, complexity of projects, and long-term business goals.

If you decide to explore laser cutting services, Sungplastic is recommended as an expert provider of sheet metal laser cutting services. We can offer the expertise and capabilities needed to meet your manufacturing requirements.

Alternatives to Laser Cutting

If you’re considering alternatives to sheet metal laser cutting for your manufacturing needs, there are several high-end options available.

EDM (Electrical Discharge Machining)

EDM utilizes electrical discharges or sparks to cut out shapes from materials. It provides a better surface finish and has a smaller heat-affected zone compared to sheet metal laser cutting. EDM is particularly suitable for cutting hardened materials, offering precision and versatility in manufacturing processes.

CNC Milling

CNC milling involves using high-speed rotary cutters to shape materials. It is a subtractive manufacturing process that works well with metals, alloys, and nonmetals. While sheet metal laser cutting uses beams of light to cut or burn designs, milling uses cutting tools to carve out or shape the desired designs. CNC milling provides high precision and is capable of handling a wide range of materials.

Waterjet Cutting

Waterjet cutting utilizes high-pressure water or a mixture of water and abrasive substances to cut through materials. It is a versatile technique suitable for various materials. While laser cutters can engrave marks or numbers, waterjet cutting is primarily focused on cutting. Waterjet cutting can handle thicker materials compared to sheet metal laser cutting, with capabilities up to 50mm. Sheet metal laser cutting, on the other hand, excels in tolerance levels and intricate details, making it a preferred choice for complex geometries.

Punching

Punching involves using a punch press to cut shapes from materials. It is a highly precise technique commonly used in CNC operations and is suitable for a wide range of materials. However, punching may not be ideal for fabricating components with complex geometries, as it is better suited for simpler shapes.

Consider the specific requirements of your project, including the material, level of precision needed, and complexity of the designs, when choosing the most suitable alternative to sheet metal laser cutting.

Laser Cutting Services for Sheet Metal Parts

Rapid prototyping uses laser cutting as a tool to cut materials. We gave you an introduction to the types, operation, and other possible information. We think you now know a little bit more about sheet metal laser cutting than before.

We are a reputable business offering sheet metal fabrication services for bespoke production and quick prototyping. We promise to deliver top-notch sheet metal laser cutting services, and we offer affordable, on-demand solutions in response to your needs.

Additionally, we provide high-volume production as well as low-volume prototypes. Even when working with custom items that have intricate elements, you can be confident that when you engage with us, your products will be free from sheet metal fabrication issues. Additionally, we provide some of the top CNC machining, 3D printing, injection molding, and die casting services.

Welcome to contact us for any questions.