The automotive, aerospace, construction, and electronics industries all have one thing in common: Their need for accurate, high-quality component parts. These industries, along with many others, can benefit greatly from laser cut sheet metal fabrication technology-perfected machinery. Technology is always improving and with these improvements comes a necessary increase in efficiency and accuracy. The demand for tightly woven tolerances, along with intricate details, continue to grow over time. In this article, we will detail the inner workings of laser cut sheet metal fabrication, how it boosts accuracy and why a reliable sheet metal fabrication manufacturer is the crux of achieving incredible output.
Everything You Need to Know About Sheet Metal Laser Cutting
With laser-cut sheet metal fabrication, high precision cutting, engraving, or shaping of metal sheets is achieved using a laser beam with extreme power. The process begins by creating a laser beam using a CO2, fiber, or an Nd:YAG laser, which is then concentrated with lenses and mirrors. These lenses focus the beam’s energy to a tiny spot. Once the laser hits the metal sheet, the surface of the material is melted, vaporized, or burned. Advanced controls CNC enable preprogrammed motion of walls and work pieces result is that the tool moves along the required contour.
Efficient handling of sophisticated designs is achieved through the use of laser cutting. The level of precision is unparalleled and achieves the best results with the least amount of secondary machining. Not only are the cuts precise, but they also have minimal area that is affected by heat. This precise along with detailed cutting saves time when it comes to part machining, resulting in improved productivity. Even with a vertical increase in production volume, manufacturers of sheet metal fabrications can maintain quality now that laser cutting is introduced. Turnaround times are also significantly improved.
Improving Efficiency and Accuracy With Laser Technology
There is a significant improvement to accuracy when laser cutting is streamed into the workflow, this is caused by automation and adds use of minimal material. Because the laser beam is focused at a single point, it allows ranges of extremely slim kerf widths, and the level of accuracy achieved makes fabrication of metals much easier. Reduction of human error is achieved through the use of CNC control systems that follow digital designs.
One more accuracy contributing factor is the reduced heat-affected zone. The traditional techniques of cutting like mechanical shearing or plasma cutting have an extensive heat input that can oftentimes melt or even bend metal. Laser cutting utilizes a highly focused heat source which almost eliminates thermal expansion and distortion resulting in higher part accuracy and consistency. Furthermore, laser cutting is a form of non-contact cutting which means no mechanical force is applied to the material. This prevents any form of deformation, ensuring that fragile or thin materials are cut without being ruined. A laser cutting’s effectiveness on achieving precise clean cuts enables a sheet metal fabrication manufacturer to create components that operate within tight tolerances enhancing the overall functionality and dependability of the product.
Another benefit of laser cutting is its high level of efficiency. Custom designed tools for each shape in traditional cutting are laser cutting’s bane. Changing designs can often be done quickly and easily, requiring minimal work and no custom tailored tools. Thus, both prototyping and mass scale production can be done effortlessly. Economically, modern businesses save dollars as their hyper-efficient industrial laser systems further reduce production cost by cutting materials at a speed unmatched by their competitors. Their proprietary cutting techniques optimize the amount of leftover material at the end of the sawing process, drastically lowering their expenses.
Recommended Materials and Thickness Ranges for Laser Cutting
Different thicknesses of diverse materials can be worked on by manufacturers across the globe, demonstrating the functional flexibility of laser cutting technology. Stainless steel, Carbon steel, Aluminum, Copper, Brass and even titanium are all parts of a laser cut sheet fabrication. Each material has unique properties that affect how the laser interacts with it. Using CO2 lasers will make cutting aluminum and copper, two very reflective and conductive metals, much more difficult than using fiber lasers. On the other hand, stainless steel and carbon steel, due to their lower reflectivity and higher absorption of laser energy, are much simpler to cut.
Thickness is an important consideration when it comes to the laser cut. While CO2 lasers cut with a higher intensity through thicker sheet metals, a fiber laser works better on thinner and moderately thick metals. Laser cutting processes are most efficient on sheet metals with steel thickness not exceeding 25mm and aluminum with 15mm. The cutting speed with which the metal can be worked on and the edge quality both are courtesy of the power of the laser, its focal length, and the type of cutting gas that is employed. For example, it cuts faster with oxygen, but does leave a hint of oxidation on the edges. Nitrogen assists in a slower cut with a cleaner edge, but means cutting at a slower pace. A qualified sheet metal manufacturing expert knows meticulously how to deal with these options to achieve an accepted quality of the edges with optimal speed and middle accuracy.
Why the Right Sheet Metal Fabrication Manufacturer Can Make a Difference
Selecting the appropriate supplier for sheet metal fabrication is crucial to maximizing the advantages of laser cutting. An authoritative manufacturer will not only possess advanced laser cutting machinery, but will also employ skilled workers who understand the relationships between the material’s properties and the cutting techniques. That way, they can guarantee that every part’s cut is made as perfect as possible with regard to quality and defects, if any. A reliable manufacturer will also provide material and design selection, as well as post-processing services that add to the product’s value and that of the customer’s expenditure.
The benefit of working with the well-known manufacturer is that every phase from the fabrication design, prototype, production, and finishing is well organized, which leads to better control of time and costs. This also increases the chances of completing the project on time and on budget. A reputable manufacturer is expected to have the latest information concerning advancements in laser cutting technology so the clients can take advantage of new materials and up-to-date methods. If the customer calls for intricate components of a product in the aerospace, automobile, and industrial sectors, collaborating with a specialist sheet metal fabrication manufacturer eliminates the uncertainties of achieving required precision, strength, and durability of the products.
Final Thoughts
One prime example is laser cutting design in fabrication of sheet metal parts. It represents both a process as well of an industry. The innovation of lasers into the manufacturing sector brought forth breakthroughs that redefine accuracy, flexibility, and speed of taking on complex tasks. Because of the efficiency of modern CNC controlled fabrication and laser systems today, a great deal of sophisticated structures can be made with uniform quality, minimum wasteful expenditure of materials, and effortless achievement of refinement for even the finest details. Apart from the automotive and aerospace sectors, laser sheet metal cutting is useful in construction and electronics. The effectiveness demonstrated by these techniques working to exacting tolerances while simultaneously accomplishing high rates of speed with minimal distortion of the working material makes laser cutting the most advantageous method for achieving quality metal machine parts. As much as there are numerous approaches to metal cutting, working with reliable sheet metal fabricators allows one to embrace the full advantages offered by lasers. Parts manufacturing takes expertise and out of Fablab’s equipment enables Fablab to produce parts with astounding quality, long service life and high strength while also having to meet very difficult requests at low pricing.
