How Laser Cutting Works?

Laser cutting, which is a thermal based non-contact process, is one of the widely established processes to cut or engrave a wide range of materials such as metals, plastic and wood, among others. The technique is one of the fastest cutting process available that assures a high degree of precision and accuracy without causing deterioration on your material. Laser cutting allows creating complex geometrical shapes, small holes, and beveled parts without generating heat compared to other thermal cutting processes. This non-contact process is highly accurate, yields excellent cut quality, with a reduced chance of material warpage. Although a widely popular technique, most of us are not aware of the working of laser cutting. The post is intended to provide you with a step by step description of laser cutting processes.

The Basics of Laser Cutting

Understanding the Laser

Laser stands for Light Amplification by Stimulated Emission of Radiation. It is a device that emits a highly focused and intense beam of light through the process of optical amplification. This coherent light beam is used for various applications, including cutting.

The Cutting Process

Laser cutting works by directing the laser beam onto the material’s surface. The concentrated energy of the laser beam heats, melts, or vaporizes the material, creating a precise and clean cut. The beam’s intensity, focus, and speed determine the depth and quality of the cut.

Materials Suitable for Laser Cutting

Laser cutting is highly versatile and can be used on a wide range of materials, including metals, plastics, wood, ceramics, and more. The process’s adaptability makes it a go-to choice for industries as diverse as automotive, aerospace, electronics, and fashion.

Laser Cutting Techniques

CO2 Laser Cutting

One of the most common techniques is CO2 laser cutting. This method employs a carbon dioxide gas mixture as the lasing medium. CO2 lasers are excellent for cutting non-metal materials, such as wood, acrylic, and fabric.

Fiber Laser Cutting

Fiber lasers use a solid-state lasing medium, often a fiber-optic cable doped with rare-earth elements. These lasers are highly effective for cutting metals with incredible precision and speed, making them indispensable in industries that demand intricate metalwork.

Nd:YAG Laser Cutting

Neodymium-doped Yttrium Aluminum Garnet (Nd:YAG) lasers are known for their high energy levels. They are commonly used for cutting and engraving, especially on thin materials and for applications that require minimal heat-affected zones.

Advantages of Laser Cutting

Precision and Accuracy

Laser cutting offers unparalleled precision, allowing for intricate and complex designs that would be challenging or impossible with traditional cutting methods. The narrow laser beam minimizes material wastage and ensures accurate cuts.

Speed and Efficiency

The concentrated heat of the laser beam results in faster cutting speeds compared to conventional methods. This increased efficiency translates to higher productivity and shorter project turnaround times.

Minimal Post-Processing

Laser cutting produces clean edges that often require little to no additional finishing. This minimizes the need for post-processing, saving both time and resources.

Versatility

As mentioned earlier, laser cutting can handle a wide range of materials. This versatility makes it an attractive choice for businesses dealing with various materials and products.

Automation and Reproducibility

Laser cutting processes can be automated, leading to consistent and reproducible results. This automation reduces the chances of human error and ensures uniform quality across multiple pieces.

Applications of Laser Cutting

Industrial Manufacturing

Laser cutting is extensively used in industrial manufacturing for fabricating components, parts, and prototypes. It’s particularly valuable in industries where precision and consistency are critical.

Art and Design

Artists and designers have embraced laser cutting for its ability to translate intricate digital designs into physical creations. It’s used to craft detailed sculptures, intricate jewelry, and customized home decor items.

Medical Devices

The medical industry benefits from laser cutting for creating precision components for medical devices, implants, and surgical instruments. The non-contact nature of laser cutting reduces contamination risks.

Electronics

The electronics sector utilizes laser cutting for precise PCB (Printed Circuit Board) manufacturing, creating intricate patterns and connections on electronic components.

Laser cutting works by focusing a laser beam on to a workpiece. The following steps will help you understand the process better.

1. First and foremost, it is extremely important to use the right type of laser cutting machine to get the job done as several models are available in the market. Consider the power consumption, cutting speed and other proven features and specifications before deciding on a model.
2. Prepare the material to be cut, it can be wood, plastic, cardboard, foam, fabric, and thin sheets of metal.
3. Choose an image to be cut or engrave on to your workpiece and upload the same to the software (commonly used are Adobe Illustrator and CoreIDRAW) compatible with the machine. The image can be a photo, a computer drawing, or a computer text.
4. Match the dimensions of the image with that of the material to be cut. This is one of the crucial steps as a minor flaw can lead to improper cutting or engraving.
5. Now, place the material to be cut on a perforated table inside the laser cabinet. Again, the step is crucial as the right placement determines the cut quality.
6. Clean the lens of the machine gently using a cotton wool before each cutting process.
7. Now that the material to be cut is in the right position. The next step is setting the lens height as this helps focus the laser at the correct level. Some machines are equipped with an automatic lens height sensor or button. If your machine doesn’t have this option, you may manually adjust the height to the required position.
8. In every laser cutting machine, there is a button named fume extractor. You must turn this switch ON as it plays a major role in extracting the fumes released during the cutting procedure.
9. Now it’s the time for print setting. There will be an option for material setting in the laser machine. Feed the type of material you are about to cut. This helps the machine to adjust the laser intensity according to the type of material being cut. For example, the machine applies pressure intensely while cutting metal than when cutting wood or foam.
10. Choose the type of cutting you prefer, you may choose vector print and raster.
11. Once calibrated, the machine makes the initial cut, which can be checked and analyzed by the operator for the cut quality and for other specifications. Ensure not to move the material during the cutting process. Once the cutting is completed in par with the parameters set, the workpiece can be taken off the machine.

At the end of these steps, you will get the material with improved edge quality and surface finish. However, to get the expected quality and precise cutting/engraving, it is important to choose the right laser cutting machine, as mentioned earlier, to facilitate accurate and intricate work. Check out your supplier’s offerings and choose the best one that fulfills your requirements completely in terms of performance, cutting quality, and cost, among others. You can visit the web page of Woodward Fab, which is amongst the leading provider of sheet metal fabrication tools and equipment! Get in touch with the company’s representative and see what they can offer to make precise and clean cuts/engraves on a wide range of materials.