Demystifying How Laser Cutting Works

 

September 24th, 2024, Laser Cutting

 

 

Laser cutting is a powerful technology that has transformed the manufacturing industry, enabling the precise and efficient production of a wide range of components. Whether you’re a seasoned professional or new to the world of manufacturing, understanding how laser cutting works can provide valuable insights into its capabilities and benefits. In this article, we’ll break down the process, from the basics of the technology to the different types of laser cutting processes available.

 

 

 

Understanding the Basics of Laser Cutting Technology

 

At its core, laser cutting is a process that uses a high-powered laser beam to cut, engrave, or shape materials. The laser itself is a concentrated beam of light that can be directed with intense precision, allowing it to cut through materials with minimal waste. The technology behind laser cutting is grounded in the principles of optics, electronics, and thermodynamics, making it one of the most advanced manufacturing methods available today.

 

The laser beam is generated by producing increased energy in a lasing medium—such as carbon dioxide (CO2), neodymium-doped yttrium aluminum garnet (Nd), or, in the case of BSG, fiber optics—inside a resonator. This energy is then focused through a series of mirrors and lenses to create a highly concentrated beam. When this beam is directed at a material, it heats the material to its melting, burning, or vaporization point, allowing it to cut through the material with precision.

 

One of the key advantages of laser cutting technology is its ability to produce complex shapes and fine details without needing to make contact with the material. Increased contact in the manufacturing process can result in disruptions in the cut material, but laser cutting forgoes this pain point. This makes it an ideal choice for a wide variety of applications, from cutting metal sheets to engraving intricate designs on surfaces.

 

 

How Laser Cutting Works: Step-by-Step

 

1. Design and Programming: The first step in the laser cutting process is to create a digital design of the part or component to be cut. This design is typically created using Computer-Aided Design (CAD) software, which gives full control over dimensions and shapes. Once the design is complete, it is converted into a format that the laser cutting machine can interpret, usually through a process called Computer-Aided Manufacturing (CAM).
2. Material Preparation: The material to be cut is then placed on the worktable of the laser cutting machine. The type of material used can vary widely. For BSG, our laser cutting is limited to certain metals, but some machines are capable of cutting through plastics, wood, and even fabrics. 
3. Laser Generation: The laser cutting machine generates the laser beam by exciting the lasing medium inside the resonator. The type of laser used depends on the material and the specific cutting requirements. BSG’s laser cutting machine uses a fiber laser, but other machines may use a CO2 laser. CO2 lasers are commonly used for cutting non-metallic materials, while fiber lasers are preferred for cutting metals.
4. Focusing the Laser: The laser beam is directed and focused onto the material using a series of mirrors and lenses. This focused beam is incredibly powerful, allowing it to cut through the material with high precision. The diameter of the beam when it touches the material is typically very small, often less than 0.1 millimeters, which enables the production of fine details and sharp edges.
5. Cutting Process: As the laser beam interacts with the material, it heats it to the point of melting, burning, or vaporizing. The machine’s control system moves the laser head along the cutting path defined by the digital design. Depending on the settings, the laser will either cut through the material entirely or only engrave the surface layer. 
6. Assist Gas: In many laser cutting applications, an assist gas (such as oxygen, nitrogen, or air) is used to blow away molten material from the cutting area. This helps to improve cutting quality by preventing material buildup on the edges. At BSG, we use both oxygen and nitrogen as an assist gas interchangeably, depending on what is best practice for the application.  
7. Post-Processing: After the cutting process is complete, the cut parts are removed from the worktable. Depending on the material and the application, additional post-processing steps, such as cleaning, deburring, or finishing, may be required. 

 

 

Different Types of Laser Cutting Processes

 

Laser cutting can be performed using several different techniques, each suited to specific materials and applications. The three primary types of laser cutting processes are:

 

• Fusion Cutting: Fusion cutting involves using an assist gas, typically nitrogen, to blow molten material out of the cut zone. This method is often used for cutting metals like stainless steel and aluminum, as it produces clean, oxide-free edges.
• Vaporization Cutting: In vaporization cutting, the laser beam heats the material to its boiling point, causing it to vaporize. This process is commonly used for cutting thin materials, such as wood, plastics, and some metals, where a high level of detail is required.
• Thermal Stress Cracking: Thermal stress cracking is a specialized process used for cutting brittle materials like glass or ceramics. The laser creates thermal stress on the delicate material, causing the material to crack along the desired cutting path.

 

Each of these processes offers unique advantages, and the choice of technique depends on the specific material and the desired outcome.

 

 

Explore Laser Cutting with BSG's Laser Cutting Machine

 

At BSG, we specialize in providing cutting-edge laser cutting solutions designed to meet the diverse needs of industries like automotive, construction, oil and gas, and more. Our laser cutting machine is engineered to deliver unparalleled precision, speed, and flexibility, making it ideal for a wide range of applications. 

 

Whether you’re looking to enhance your production capabilities or explore new design possibilities, our laser cutting machine offers the tools you need to achieve your goals. With BSG’s advanced technology, you can produce high-quality parts with minimal waste, reduced lead times, and enhanced consistency.

 

Discover how BSG’s laser cutting solutions can help you stay competitive in a demanding market. Contact us today to learn more about our services and how they can benefit your business.