Want to learn more about the process of laser cutting? You’ve come to the right place. In this blog, you will find a detailed explanation of the entire process in layman’s terms. Simply put, laser cutting is a technology that utilises a focused, high-power laser beam to cut or engrave materials.
It is a computer-controlled technology that directs the laser along a digital path to precisely cut materials like metal, wood, acrylic, and fabric. The laser cutting process is extremely accurate for complex designs, as it produces smooth and high-quality finishes.
What Are The Different Types of Laser Cutting?
There are multiple variations of the laser cutting process. Each different type is highly accurate and ideal for a particular application. Here is a list of all the types, with a description of how they work:
CO2 Laser Cutting
CO2 lasers are one of the earliest and most popular types of lasers. They use a powerful, focused beam of infrared light that is generated by an electrically excited carbon dioxide gas mixture to cut materials.
CO2 laser cutting comes with two options: using Oxygen or Nitrogen gas. Oxygen gas is preferred for thicker materials, while Nitrogen is preferred for thin sheets. Since the CO2 laser creates an oxide layer on the cut surface, pre-treatment processes such as blasting are required to avoid this.
Fibre Laser Cutting
Fibre laser cutting utilises optical fibre for light amplification instead of conventional gas discharge. For this, the light emitted through laser diodes is passed through the optical fibre. This makes the beam strong enough to melt away stainless steel up to 1 cm in thickness.
A strong airflow system often accompanies the light beam to push away the molten material for a clean cut. The fibre optics of these lasers makes use of several elements like Ytterbium, Neodymium, Erbium, and Dysprosium.
Nd:YAG Laser Cutting
Nd:YAG is the abbreviated form of Neodymium-doped Yttrium Aluminum Garnet. As a replacement of gas discharge or fibre, Nd:YAG crystals are used for an amplified beam. These lasers are capable of producing both continuous and pulsed laser beams.
Excimer Laser cutting
Excimer is the combined term for Excited Dimer. This type of laser cutting uses an ultraviolet laser beam. Excimer is mostly used in small-scale precision cutting processes. Some common examples are eye surgery, stent cutting and wire stripping.
Direct Diode Laser Cutting
Direct Diode Laser (DDL) incorporates the usage of a laser beam directly from the diodes. There is no amplification medium like gas discharge or fibre. The diodes themselves produce a laser beam strong enough for the cutting process. This type of laser cutting has very high efficiency.
Various Laser cutting applications
Laser cutting is a process that is widely used across various industries due to its precision and efficiency. It is commonly utilised in automotive for sheet metal cutting, in aerospace for making aircraft components and in manufacturing for processing materials.
In electronics, it helps produce precise parts for devices like smartphones and laptops. Laser cutters are also made use of in advertising for the creation of smooth-edged signage and logos. In architecture, a laser cutting company helps make decorative elements, while in healthcare, it serves the purpose of manufacturing medical devices and surgical tools.
Applications of laser cutting in other industries:
- Automotive: Sheet metal cutting for components like exhaust systems and frames.
- Aerospace: Precision parts for aircraft, turbine blades, and smaller components.
- Manufacturing: Used in assembly lines for metal, plastic, and textile processing.
Laser cutting advantages and disadvantages
This process comes with numerous benefits and a few limitations. Going through each one in detail, you will have a thorough knowledge of the pros and cons that come with laser cutting services.
Advantages
- Accuracy: Laser cutters have the highest precision among any cutting methods. Its cutting accuracy is even higher than processes like water jet cutting.
- Speed: Laser cutting thin materials is a very swift process. The speed can easily reach over 3 meters per minute. This makes it ideal for mass-production assembly lines.
- Versatility: Laser cutting works on a lot of different materials and has many different uses. This makes it a very versatile method of cutting.
- Customisation: Personalised and customised shapes can be created by simply changing the CNC program.
- Automation: Modern CNC laser cutting works through CNC systems that automatically control the movement of the cutting head.
- Dust-free Cutting: Cutting with a laser does not create any material dust in the workpiece. For example, there is no sawdust when cutting wood.
- Reduced Waste: A laser cutter is very precise and removes very little material from the workpiece. This quality comes in handy when cutting precious metals, where wastage is a great loss.
Disadvantages
- Cost: Laser cutters are industrial equipment. Their initial investment can be hefty, while maintenance costs are also high for those who are on a tight budget.
- Safety: Safety is not a major concern with modern lasers since they come with safeguard measures. However, their operators still require safety training.
- Material limitation: Certain materials are unsafe for cutting with a laser. It is important to know what laser cutting materials are to avoid machine damage and human injury.
- Thickness: Laser cutting works well for thin materials like sheet metal, but not for thick materials like metal blocks.
Laser Cutting Vs Plasma Cutting
| Laser Cutting | Plasma Cutting | |
| Power Source | Light | Electric Arc/Gas |
| Materials | Metals, wood, plastic, etc. | Conductive metals only |
| Precision | High | Moderate |
| Thickness | Better for thin/complex parts | Excels with thick metal |
| Cost | Comparatively high | Comparatively low |
Conclusion
Laser cutting is a highly advanced and versatile manufacturing technology that has transformed the way materials are processed across industries. By using a focused computer-controlled laser beam, it delivers exceptional accuracy with speed and clean finishes. Additionally, laser cutting services are subject to strict quality control standards under ISO 9001, making them ideal for high-quality production.
With several laser types such as CO₂, fibre, Nd:YAG, excimer, and direct diode, laser cutting suits a wide range of materials and applications. While the technology offers clear advantages in precision and reduced waste, factors such as cost and material limitations must also be considered. Overall, laser cutting remains a powerful and reliable solution as compared to plasma cutting, where precision and efficiency are prioritised.
Frequently Asked Questions (FAQs)
- How does laser cutting actually work?
Laser cutting works by focusing a high-power laser beam onto a material. The intense heat cuts the material along a computer-controlled (CNC) path. An assist gas, such as oxygen or nitrogen, blows away the molten material to create a clean and precise cut.
- Do lasers use AC or DC?
Lasers typically use electricity to operate. In laser cutting machines, electrical power (usually AC) is converted into DC power inside the system to run components such as laser diodes and control electronics.
- What cannot be cut with a laser cutter?
Certain materials are unsafe or unsuitable for laser cutting. These include PVC and vinyl, which release toxic gases. Some coated or reflective materials and very thick metal blocks that exceed the laser’s cutting capacity are also not suitable.
- Why is laser cutting good at making things accurate?
Laser cutting is highly accurate because the laser beam is extremely focused and computer-controlled. This allows the machine to follow digital designs exactly and cut complex shapes with minimal material waste.
- What metals are best for laser cutting?
Laser cutting works best on thin to medium-thickness metals such as stainless steel, mild steel, aluminium and some alloys. Fibre lasers are especially effective for cutting metals like stainless steel with high precision.
