If you have been searching for cutting tools, you have likely considered laser cutters. You must have heard of several other tools like mills, bandsaws, and shears. It will not come as a surprise to you that laser cutters are far superior to other devices when it comes to subtractive manufacturing. You can rely on the laser cutter when you need clean, precise, and accurate cuts. By exploring these state-of-the-art machines, we will give you a solid understanding of your cutting needs.
How Does Laser Cutting Work?
If we want to understand laser cutters, we have to start with the concept of laser itself. A laser is nothing but a powerful beam of infrared light. The most common way to generate a laser is by exciting gas atoms in a chamber. The colliding atoms release photons of light that are known as lasers. Laser machines amplify this beam by reflecting it and releasing it from a thin nozzle. The beam is very hot. When it comes in contact with the material, it evaporates. The thermal separation of the material results in a seamless cut. Despite this straightforward principle, there are many laser cutters available. Let’s explore the numerous types of laser machines.
CO2 Laser Cutting
Let’s talk about gas atoms and laser beams. CO2 lasers contain a gaseous mixture of carbon dioxide, nitrogen, helium, and hydrogen in the laser chamber. In today’s market, they are the most common laser cutters. Even among CO2 laser cutters, there are two further sub-categories: Direct Current CO2 Cutters and Radio Frequency CO2 Cutters. DC CO2 laser cutters have electrodes placed inside the gas chamber. The gas atoms are excited when a current passes through the gas chamber. Since the electrodes are exposed to the hot gas, they can get eroded pretty quickly. Radio Frequency CO2 Cutters overcome this problem very well. They use external electrodes, bypassing the problem of electrode exposure.
Fiber Laser Cutting
For years laser machines suffered from an efficiency problem. CO2 laser cutters dominated the market, but there was a need for a technological leap. The research into developing more efficient laser cutters gave birth to the Fiber Laser Cutter. They are solid-state, which means that they don’t rely on a gaseous medium for laser generation. How is the laser produced then? Instead of a gas chamber, they channel a seed laser beam through an optical fiber to amplify it. It makes a small 1064nm wavelength laser that has high energy. It can cut reflective metals, wood, plastic, and ceramics. But that’s not all – fiber lasers achieve this with greater efficiency. Compared to CO2 lasers, they can provide up to 60% more efficiency!
Nd and Nd: YAG Lasers
The Neodymium-doped Yttrium Aluminum Garnet laser is another cutting-edge laser research product. Like fiber laser, this is also a solid-state laser. Instead of relying on optical fiber, it uses the Nd: YAG crystal to amplify the laser beam, much like the fiber laser. Crystal lasers are efficient and powerful. The Nd: YAG laser machine is efficient at machining both small and large-thickness workpieces. Adjusting the laser beam intensity, you can perform etching, engraving, cutting, or boring. They are used to machine many materials like metal, plastic, and ceramic.
Direct Diode Laser Cutting
Whereas other laser cutters have been experimenting with different gain media, the direct diode laser takes a different approach. Bypassing any gain medium, it directly transmits the laser from a semiconductor diode. Because the resulting laser beam does not undergo any amplification, it is known as a direct-from-the-diode laser. They are compact, robust, and deliver multiple kilowatts of power. They are suitable for cutting and engraving small to medium-thickness materials.
Where is Laser Cutting Used?
As laser cutting becomes more nuanced, more industries recognize its significance. Today, it is seen everywhere – from manufacturing to art. Let’s go through its fundamental applications.
Metal
Laser cutting is increasingly becoming the preferred way to cut metals, not only because of its ease of operation. Conventional metal cutting tools like mills and bandsaws produce a lot of heat. This wasteful heat results in deformation and deterioration of material quality. In addition, they require stronger clamps to hold heavy workpieces. Laser cutters overcome both these obstacles. They can cut or engrave metals from aluminum to tungsten – and everything in between.
Wood
Laser cutters have breathed new life into woodworking shops by providing an all-in-one machining station. Jobs that previously took time and effort now take a few minutes. Traditionally, the act of etching or engraving woodwork would require the skills of a trained craftsman. With CNC laser cutters, etching wood with computer-generated designs becomes easy. Direct diode lasers are often seen in woodworking shops today, whereas CO2 cutters can fulfill more heavy-duty roles. Laser cutters can cut many types of wood, such as softwood, hardwood, and plywood.
Plastics
If you want burrless and smooth edges on your plastic, laser cutting is the most versatile option. Even moderate-power laser cutters can easily cut through medium-density plastic. Laser cutting has enabled many plastic industries, such as art, ornamentation, utility items, and utensils. It is important to remember health hazards since some plastics can produce poisonous fumes when melted. However, plastics like acrylics, polypropylene, mylar, polycarbonate, and others are safe to cut with a laser.
Glass
Glass is one of the most brittle and delicate manufacturing materials. Laser cutting is particularly effective here because of its non-contact nature. With the proper adjustment of the laser beam intensity, factories can manipulate glass like never before. Laser cutters can cut, etch, and engrave glass items by exercising fracture control. It is particularly useful for decorative pieces, utensils, and trophies.
The Advantages
So, how can we sum up the benefits provided by laser cutters? Firstly, they are a non-contact cutting method. This makes them highly suitable for cutting delicate materials like glass and plastic. Additionally, they save the effort of clamping down heavy materials. Even though laser cutters generate heat, they fall into the category of low-thermal stress machines. They can cut accurately and precisely while reducing the risk of damage due to heat.
The Disadvantages
The main disadvantage of laser cutting is efficiency. Commonly used CO2 laser cutters are highly inefficient. They may consume up to 3 times the power output, leading to enormous electricity bills. In addition, lasers that use optical amplification require regular maintenance. Gold-plated reflective mirrors can be costly to repair or replace, further driving up the operational cost.
FAQs
What is Laser Cutting?
Laser Beams are high-energy infrared light rays emitted by gaseous atoms. Laser-cutting machines channel these beams into a point, vaporizing the material in touch. This process is known as laser cutting.
What are the Main Components of a Laser Cutting Machine?
The main components of a laser cutting machine are the power supply, laser resonator, cutting head, mechanical system, and motion control system.
What are the Laser Cutting Parameters?
Before you set up a laser cutter in your factory, you must become familiar with the several parameters that affect its performance. Factors like laser power and cutting speed impact device performance. Pulse frequency, duration, and wavelength are additional parameters for the materials it can cut. Maintaining the correct focal setting, gas, and pressure is critical during laser cutter operation.
Are There Several Methods of Laser Cutting?
The various methods of laser cutting are vaporization, fusion, laser flame, fracture-controlled, stealth dicing, and vector scoring.
What is the Power Consumption in Laser Cutting?
Laser cutting requires enormous power consumption, typically in the 0.1kW to 15kW range. CO2 lasers are highly inefficient. Their efficiency can be as low as 5%, meaning that the majority of energy emitted by gas atoms is wasteful heat.
How Long do Laser Cutters Last?
Fiber laser cutters have the most extensive lifespan. A good quality fiber laser can last you for 100,000 hours or 45 years. CO2 laser cutters have a shorter life, with the average machine lasting for 30,000 hours, equivalent to 15 years.
What are the Similarities Between Laser Machining and Cutting?
Since both these terms sound similar, it is natural to confuse one with the other, but there are some key differences. Laser cutting entails using laser technology to cut, slice, or bore through materials. Laser Beam Machining employs a laser for finer tasks such as engraving, etching, or micro-machining. It manipulates material by removing the upper layer and modifying its surface geometry.
How do You Choose the Right Type of Laser for Your Project?
Wondering what type of laser will suit your project? You are not alone! Laser cutters have applications in numerous industries, from automotive to medical. The answer to the question lies in your particular use case. Consider the laser technology you need: CO2, fiber, or direct-diode. Space is also a crucial factor. Choose a machine with a bed size that fits the floor space of your factory. Finally, never forget to evaluate your budget. Fiber or crystal laser cutters are top-tier, but they are also expensive. Whatever your budgetary restrictions, it is recommended to go for a high-quality laser cutter.
Where to Buy a Laser Cutter?
MIHARMLE provides superb-quality laser cutters trusted by thousands of manufacturers across the globe. As a leading professional manufacturer of laser cutters, we have a wide range of machines available for you. You are sure to find the right laser cutter for your business in our catalog. Click here to view the product catalog. Our team is filled with industry experts who are enthusiastic about assisting you in the decision-making process. Contact us for an expert counseling session on the capabilities of our laser-cutting machines. We aim to help emerging businesses like yours prosper and reach new heights!