Laser cutting is one of the most common material processing techniques. It uses high-powered lasers to cut through materials including wood, metals and plastics. In this article, we’ll explain how laser cutting works, look at the different types of laser cutting, and explore its many advantages. Contents What is laser cutting? How does laser cutting work? Components of a laser cutting machine Types of laser cutting Which materials are suitable for laser cutting? What is laser cutting used for? What are the advantages of laser cutting? Are there any disadvantages of laser cutting? Laser cutting safety considerations Laser cutting FAQs Precision laser cutting solutions by Novanta Photonics What is laser cutting? Laser cutting is a precision manufacturing process that uses a focused, high-power laser beam to accurately cut through industrial materials. The heat generated by laser beams can melt, burn or vaporize even the toughest materials, including metals and acrylics. Laser cutting can create clean-cut or rounded edges, tapered cuts, and intricate, complex designs. It’s used by industries including the aerospace, automotive and electronics sectors for rapid prototyping and manufacturing. Novanta Photonics’ laser cutting solutions enable seamless customization via advanced laser control software, making the technique incredibly versatile and adaptable. How does laser cutting work? Regardless of the type of laser used, the laser cutting process will comprise the following steps: 1. Laser beam generation Laser light is generated within the laser, with the light generation depending on the type of laser medium used e.g. CO2 or solid state. The resulting beam exhibits a high power density and possesses a wavelength specific to the type of laser. 2. Laser beam direction Mirrors or fiber optics are used to direct the laser beam to a lens that focusses the beam to a small spot on the surface of the material. 3. Material processing When the focused laser beam comes into contact with the material, its power generates heat that melts, burns or vaporizes the material that is no longer required. A jet of gas can be used to assist the cutting process, blowing away residuals, resulting in a high-quality edge. 4. Post-processing Laser cutting produces a cleaner, more precise finish than other cutting methods, but manufacturers may complete the process by cleaning or deburring the newly cut area during post-processing to ensure the highest quality finish. Components of a laser cutting machine An industrial laser cutting machine will have the following components: Laser source: the laser could be a CO2, fiber or Nd:YAG laser, and this is the key component that creates the laser beam. Selecting a laser with the correct wavelength that matches the absorption of the material can increase the cutting speed and have a positive effect on the cutting quality Optics and beam delivery: there are two common types of beam delivery; a scan head uses galvo mirrors to steer the focused laser beam across the material surface, or a cut head, containing a fixed focusing lens and a gas jet manifold. Read more about choosing the correct beam delivery method. Control software: a controller manages the laser cutting machine and the auxiliary components. It can direct the beam to the precise location or monitors the movement of the material. A comprehensive software supports the cutting operation by precisely adjusting the parameters like laser power and process speed, or creating cutting jobs. Work table: the material being processed is held on a surface, often featuring a grid structure, while it is being cut. It is also possible to work on the fly and cut the material while it is moving on a conveyor or robotic arm. Types of laser cutting There are several types of lasers used in laser cutting, with each suitable for different materials or applications due to their distinct wavelength. 1. CO2 laser cutting CO2 lasers are frequently used in industrial laser cutting, as they are able to precisely cut through a wide range of materials, including thin metals, acrylics, ceramics, wood, glass, and more. The laser beam is generated via a gas mixture featuring carbon dioxide. CO2 lasers are favored by many manufacturers for their versatility in cutting a variety of materials, their cost, reliability, and robustness. 2. Fiber laser cutting Fiber lasers often use solid state laser technology to generate the beam. The fiber is used to amplify the laser power, which enables the laser to cut through metals, including aluminum and stainless steel. This type of laser cutting utilizes high-energy laser beams and can operate at high speeds, supporting overall efficiency. 3. Solid state laser cutting There are several different types of lasers using crystals as the laser medium, including Nd: YVO (neodymium-doped yttrium orthovanadate). This type of laser is typically used in cutting applications that require an enhanced level of intricacy. However, it can be more expensive than other forms of laser cutting, as they require more frequent maintenance and replacement. Which materials are suitable for laser cutting? Laser cutting is an incredibly versatile technique that can be used to process a wide range of materials, including: Metals, including aluminium, steel and copper Plastics, including acrylics Wood Cardboard Paper Thin film Textiles Glass Ceramics Leather Rubber Every material has a unique absorption spectrum; matching the laser wavelength to the material’s absorption can improve the cutting speed, edge quality and minimize thermal effects. However, there are also some materials that aren’t suitable for laser cutting, as they become a fire risk, release toxic fumes, or risk damage to the laser cutting machine. Materials that shouldn’t be laser cut include: Carbon fiber Polyvinyl Chloride (PVC) Polyvinyl Butyral (PVB) Teflon (PTFE) Any materials containing halogens (fluorine, chlorine, bromine, iodine and astatine) Certain metals can pose a health risk, such as Chromium and Manganese What is laser cutting used for? Thanks to its versatility, industrial laser cutting solutions are used across multiple sectors to achieve precision and drive efficiency. Industries that use laser cutting include: Automotive: car manufacturers use lasers to manufacture a wide range of components from high-precision metal parts and plastic panels for the interior to safety features like airbags Aerospace: air and spacecraft manufacturers use laser cutting technology to craft complex composite materials with the precision required to meet industry safety and design standards Electronics: in the electronics sector, laser cutting is used to manufacture intricate micro-components, such as circuit boards or connectors. With the decreasing size of electronics, the precise nature of laser cutting becomes more viable for this industry Medical device manufacturing: laser cutting is crucial for the medical sector. The industry depends on precision manufacturing, as surgical tools, implant parts and medical machines require components that exhibit a clean and smooth cut without sharp edges Fashion: the fashion and textiles industry uses laser cutting machines to create detailed designs on fabrics or leather with speed and efficiency. This fast-paced industry benefits from the high flexibility provided by laser cutting technology Sign making: industries requiring precise, intricate artwork use laser cutting to accurately create designs on a range of materials, including many metals What are the advantages of laser cutting? From enhancing productivity to improving cost efficiencies, industrial laser cutting can deliver many advantages. These include: 1. High precision Laser cutting is increasingly used by manufacturers over traditional cutting techniques due to the extreme precision and accuracy it provides. Novanta Photonics’ laser cutting solutions are engineered to produce minimal kerf, and allow highly intricate patterns to be created. 2. Improved productivity Another of the key advantages of laser cutting is its impact on an organization’s productivity and efficiency. As a non-contact process, there’s minimal toolwear and maintenance, and it’s quick to set up, supporting overall productivity and enhancing competitiveness. Laser cutting also minimizes waste, as there are no consumable parts, and its precise cuts minimize scrap material, making it a more sustainable and efficient technique than traditional cutting techniques. 3. Increased quality Its zero contact nature makes laser cutting a great tool to cut sensitive materials without any application of force, and no contamination is induced by using contact tools like cutters. By optimizing the process parameters, the quality and shape of the cutting edge can be improved and shaped to the desired result. 4. Greater flexibility Laser cutting is highly versatile and flexible, as it can be used across multiple industries in wide-ranging applications and on a variety of materials. Laser cutting software can quickly adapt to last-minute design changes or updated industry regulations to keep your organization agile and flexible, giving you an extra competitive edge. Are there any disadvantages of laser cutting? While there are many advantages of laser cutting, every processing technique has some limitations. Challenges associated with laser cutting can include: Material limitations: the thicker the material, the less effective laser cutting can become. With thicker materials (above 50mm), it can be harder to achieve clean or complete edges, impacting efficiency. What’s more, some reflective films or metals may not be compatible with laser cutting, as there’s a risk of the beam reflecting back on itself and damaging the equipment Warping: the high temperatures laser cutting produces may result in warping or other thermal damage to heat-sensitive materials, affecting the precision and quality of the final product Harmful fumes: the heat generated by concentrated laser beams can release potentially harmful or toxic fumes when processing certain materials, including some plastics Implementation cost: decision makers may worry about the initial cost of industrial laser cutting equipment, but the cost efficiencies it can generate in the long term counter this, making it a cost-effective solution Laser cutting safety considerations As with any laser technology, there are important safety considerations when using laser cutting equipment. These include: Personal protective equipment, such as laser safety goggles, should be worn to protect the eyes from laser exposure. Some types of lasers may also require gloves or other PPE to be worn Proper fume extraction is required to protect against potentially hazardous fumes and gases generated by certain materials Regular inspections help ensure optimal performance, even when tool replacement or maintenance is not required Thorough training is needed for all staff coming into contact with a laser cutting machine or accessing laser cutting software Clearly mark and restrict access to the laser cutting area to ensure only trained, authorized personnel can use the equipment. This is vital for protecting staff from potential exposure to laser-related hazards Laser cutting FAQs How deep can laser cutting go? The type of laser, its power output, wavelength, and the specific material being processed will determine the depth that laser cutting is able to achieve. Typically, metals of 25mm to 30mm thick can be cut using high-power lasers. For other materials, such as wood and plastics, a laser cutting machine can achieve depths of 50mm to 60mm. Novanta Photonics’ precision laser cutting solutions are engineered to deliver a high-precision finish, regardless of depth. How does laser cutting compare to CNC cutting? Laser cutting and CNC are both controlled using computer numerical control (CNC) technology, but the key difference between the two processing techniques is: Laser cutting uses laser beams to precisely remove material without applying force, making it ideal for intricate details and sensitive materials. CNC cutting uses a cutting tool to remove material, so it may be used for processing thicker materials and other heavy duty tasks, but at a lower speed. How does laser cutting compare to plasma cutting? While laser cutting uses a focused laser beam to cut away material, plasma cutting uses a high-temperature plasma arc to melt away material. Laser cutting can achieve greater precision than plasma cutting. Due to lower heat stress, the material requires less post-processing. Plasma cutting is only suited for metals and conductive materials, and creates a coarse cutting edge. How sustainable is laser cutting as a processing technique? Laser cutting is regarded as one of the more sustainable material processing techniques. As a non-contact method, there’s minimal toolwear, reducing the level of maintenance required compared to traditional cutting methods. Laser cutting’s extreme precision produces minimal waste, and Novanta Photonics’ solutions are engineered to integrate with existing systems to deliver long-term efficiency, further supporting sustainability efforts. Precision laser cutting solutions by Novanta Photonics At Novanta Photonics, we’ve been engineering laser cutting components and subsystems for over 35 years. Our industry-leading solutions are used by organizations across the globe to streamline efficiencies, enhance productivity, and achieve a level of precision that simply isn’t possible with traditional cutting techniques. Get in touch today to find out more about our precision laser cutting technology, and start transforming your operations. Request an Application or Material Test
