Laser Cutting
1. Laser Cutting at Batnon
At Batnon, as a laser cutting manufacture factory, we specialize in providing high-precision laser cutting services tailored to meet the diverse needs of our clients. Located in China, our state-of-the-art facility is equipped with the latest laser cutting technology, allowing us to handle a wide range of materials with unparalleled accuracy and efficiency. With years of expertise in the industry, we cater to various sectors including automotive, aerospace, electronics, and more, ensuring top-quality products and timely delivery. Partner with us for reliable, cost-effective laser cutting manufacture solutions that drive your projects to success.
2. Overview of Laser Cutting
Laser cutting is new technology for precisely cutting a wide range of different materials. The basic principle of laser cutting is utilizing a beam of light, generating from the concentrated light beam is strong energy which is powerful to cut through materials. According to designs, it can produce relative patterns of shapes while traditional cutting methods can not achieve.
3. How Laser Cutting Works
3.1 Laser generation
First a laser beam is generated from a laser resonator, the beam is directed by arrays of mirrors or optical fibers.
3.2 Focusing
Essentially laser beam is concentrating light into a beam from a laser resonator. Concentrated light converges strong power, when the power of the beam is strong enough, it can then cut materials though burning.
3.3 Cutting
Point the laser beam at the material, intense beam with strong energy will melt, burn, or vaporize the material, thus achieve cutting. Such cutting is done in a high precision way.
3.4 Movement
The pointer which directing the laser beam needs to move to cut as per the designs path, thus creating different cutting workpiece. This can be aided by automation controlled by computer.
4. Types of Laser Cutting
There’re 2 main type according to how laser is generated:
1) CO2 Laser Cutting:
This way is ideal for cutting, boring, and engraving non-metal materials such as wood, acrylic, glass, and textiles.
2) Fiber Laser Cutting:
Fiber laser cutting is known for high-speed cutting, particularly effectively work on metal materials like steel, aluminum, and copper. It has a higher energy efficiency.
5. Materials Suitable for Laser Cutting
Laser cutting works on many different material, most are commonly used or seen in daily life. This is also the reason laser cutting has become an important cutting method. These materials include:
• Metals: s.steel, aluminum, brass, copper, iron, and more.
• Plastics: Acrylic, polycarbonate, polypropylene, foam, and nearly all other polymers.
• Wood: Plywood, MDF, hardwoods, and softwoods.
• Textiles: Fabrics, leather, and other flexible materials.
• Others: Glass, ceramics, paper, and composites.
6. Advantages of Laser Cutting
There’re many advantages by laser cutting compared with other cutting methods. These advantages include:
1) Precision and Accuracy: cutting precision can be +-0.01mm, such tolerances makes it ideal for complex and intricate designs.
2) High Speed: depending on laser beam cutting moving speed, it can be adjustable for different cutting speed.
3) Versatility: laser cutting works on plenty of different materials
4) Quality: edges cut by laser beam are smooth without ripples.
5) Minimal Waste: workpiece to be cut can be arranged in a most saving way on material so least waste in cutting.
6) Automation: laser cutting finishes the work completely controlled by computer programmed in advance with specially designed cutting way.
7. Applications of Laser Cutting
Because of the above obvious advantages, laser cutting is now being widely used in many industries and environment. These include:
• Automotive: cutting high precision parts and components.
• Aerospace: making some complex shapes as parts in aircraft.
• Electronics: cutting and engraving PCB panel and housings.
• Medical Devices: making precise parts for medical equipment.
• Jewelry: crafting intricate designs and patterns.
• Signage and Display: cutting custom designed signs and display.
• Architecture: making finely design decoration pieces and architectural models.
Laser cutting is an innovative cutting method and manufacturing way for many industries, providing unmatched precision, speed, and versatility. Whether for prototyping or mass production, laser cutting has been and will be an essential manufacture method in modern manufacturing.
8. Thickness And Size Limitations For Laser Cutting
Yes, there is size and thickness limitation for laser cutting, but limitation is actually existing for any manufacturing methods. Therefore, it’s understandable for laser cutting also. The limitations depend upon material type and cutting laser itself.
Material Size Limitations:
sheet size: according to laser cutting machine work capability, workpiece sheet sizes can vary from up to 4 feet by 8 feet (1200 mm by 2400 mm), even to 6 feet by 12 feet (1800 mm by 3600 mm). this is depends on machine work capability.
Material Thickness Limitations:
1) for metal
o Carbon Steel: Up to 25 mm (1 inch) thick.
o Stainless Steel: Up to 20 mm (0.75 inches) thick.
o Aluminum: Up to 15 mm (0.6 inches) thick.
o Brass/Copper: Up to 10 mm (0.4 inches) thick.
2)Non-Metals:
o Acrylic: Up to 30 mm (1.2 inches) thick.
o Wood: including basswood, plywood, veneer, woodboard, Up to 25 mm (1 inch) thick.
o Plastics: Varies widely, typically up to 20 mm (0.75 inches) thick.
o Fabric/Textiles: Generally limited only by machine setup and handling.
Other Limitations For Laser Cutting Services
These limitations limit laser cutting performance and capability, they include:
1) Laser Power: higher power laser is able to cut thicker materials.
2) Material Type: different materials have different characteristics for cutting, i.e, metals require higher power laser than other non metals.
3) Quality Requirements: quality from laser cutting is precision and edge smoothness. Higher quality will need higher power and slower cutting speed.
4) Machine Specifications: machine itself quality will affect laser cutting result. Better machine will bring better cutting performance.
If there’s doubt for a new material not in machine cutting guide, it’s necessary to consult with the service provide to understand cutting possibility and performance in advance.
9. Customization Options
Laser cutting is also known for it wide adaptability for custom design and manufacture of specific demand.
1) Material Selection:
As introduced previously, materials for laser cutting include: Steel, stainless steel, aluminum, brass, copper.
Non-Metals: Acrylic, wood, paper, fabric, rubber, plastics.
2) Thickness:
Material thickness varies from thin sheets (0.5 mm) to thick plates (up to 30 mm for some metals and non-metals).
3) Cutting Patterns:
Laser cutting has no limitation in design or pattern, it’s able to cutting complex, Intricate and precise patterns.
4) Engraving:
Laser cutting is often used to engrave patterns, logos, text or other designs on surface of materials to create decorative effect. Even including tattoo on skin.
Deeper engraving will need longer engraving.
5) Finishing Options:
Laser cutting can also be used for enhance edge smoothness and appearance.
6) Precision and Tolerance:
Laser cutting is a high precision cutting method.
Its tolerances can be up to +-0.01mm, and such tolerance can maintain stable for a long period in cutting processing.
7) Batch Size:
Laser cutting is an idea method for small quantity manufacture, even starting from single piece. Prototyping, while it can also handle high volume production.
8) File Formats:
Some simple design file format can be workable for laser cutting,
For 2D Design Files: DXF, DWG, AI, PDF, etc.
For 3D Models: STL, OBJ, STEP, IGES, 3MF, PLY, FBX, VRML/X3D, DAE, AMF
9) Combination Processes:
Laser cutting can be combined with other processing ways to make some complex parts that single manufacture way can not do. Such as:
Laser Cutting + Bending: Combining laser cutting with bending services for forming parts.
Laser Cutting + Welding: Integrating laser cutting with welding services for assembled components.
10) Quality Control:
Inspection Services: Ensuring all parts meet specified dimensions and quality standards.
11) Benefits of Customization:
Versatility: cater to a wide range of industries and applications.
Precision: High accuracy and repeatability for consistent quality.
Efficiency: Fast turnaround times for custom projects.
Cost-Effective: Reduced material wastage and lower production costs.
10. Description of Laser Cutting Machines
1) CO2 Laser Cutting Machines
This type machine uses CO2 as the main laser medium so it’s called CO2 laser cutting machine. Wavelength of Its beam light is around at 10.6 micrometers.
Such machine is ideal for cutting non-metal material, like wood, acrylic, glass, leather, plastic, foam…
Products cut by CO2 laser cutting machine are: signage, packaging, textiles, art decoration.
2) Fiber Laser Cutting Machines
Another important type is fiber laser, it’s so called because the beam light is generated by diodes and channeled through optical fibers.
Wavelength of fiber laser light is around at 10.06 micrometers.
This machine handles metal materials, like steel, s.steel, aluminum, brass, copper.
Products made with fiber laser are widely spread, Automotive, aerospace, electronics, medical devices, and metal fabrication industries.
3) Hybrid Laser Cutting Machines
A third type machine is a combination of CO2 and fiber laser. So it can switch between the two laser source to adapt to different cutting requirement.
Wavelength varies depending on the real laser sources used.
Materials suitable for such machines: metals, plastics, wood, and ceramics.
Products cut by Hybrid laser machine include both metals non-metals.
11. Key Features Of Laser Cutting
Laser cutting processing has many features:
1) high precision and accuracy
Precision up to +-0.01mm, controlled by pre-set programs.
2) High cutting speed
The work speed is relatively much higher than any conventional cutting methods.
3) Automatically and CNC controlling
Laser machine works under CNC control system, automatic and repeatable. No human involvement is required.
4) Wide adaptability
Capable of handling a wide range of materials, from metals to non-metals, from thin to thick.
5) Clean and Smooth Cut Edge
Edges cut by laser are smooth, clean, no burrs, no need for further processing.
6) Non-contact Process
Since no pressing on the materials, there won’t bring mechanical stress on the materials.
7) Energy Efficiency
Compared with other cutting methods, laser cutting converts highly input power into useable cutting power.
At Batnon, our state-of-the-art laser cutting machines embody these features, providing our clients with top-tier cutting solutions tailored to their specific needs.
12. Quality Control Processes for Laser Cutting
Realizing high quality laser cutting involves a comprehensive quality control practice. At Batnon, we employ a series of steps to ensure excellence of our laser cutting manufacturing and services.
1) Material Inspection
o All raw materials are inspected for defects and specifications, such as thickness, composition and surface quality.
o Material certification ensures material meet industry standards.
2) Pre-Production Testing
o Prototype testing: making several prototypes with the materials and validate if it’s complying with design by laser cutting.
o Parameter optimization: adjust laser cutting settings to be more effective in power, speed, and other parameters to achieve best result.
3) Machine Calibration and Maintenance
o Regular machine calibration: conduct routine calibration on the laser cutting machine to ensure precision and accuracy.
o Maintenance: strict routine maintenance to keep laser cutting machine in good condition, avoid error or downtime risk.
4) In-Process Quality Checks
Inspection and check: inspect visual and dimensions during laser cutting processing.
5) Post-Production Inspection
Surface finish evaluation: examine cutting edge for smoothness, cleanliness, or if there is burrs.
Dimensional accuracy: check if dimensions are accurate against design specifications.
Functional check: perform functional tests to verify if the parts meet functional requirements.
6) Continuous Improvement
Feedback loop: gather feedback from customer on the products for future’s improvements.
Training: Regularly train staff on the latest quality control techniques and technologies.
Process Optimization: Continuously refine and optimize laser cutting processes to enhance quality and efficiency so that improve quality and lower cost at same time.
At Batnon, our commitment to quality control ensures that every laser-cut part we produce meets the standards of precision and reliability. By implementing these rigorous processes, we guarantee exceptional results for our clients across various industries.
13. Process Workflow of Laser Cutting
At Batnon, we build and follow a systematic approach to ensure high quality in our laser cutting services. Here’s a detailed step-by-step guide to our laser cutting manufacture process:
1) Consultation and Requirement Gathering
• Initial Consultation: understand client’s specific needs, including material type, dimensions, surface finish, coloring and design requirements.
• Requirement Documentation: file up all details and specifications to ensure clarity and accuracy before work is started at both sides.
2) Design and File Preparation
• Design Creation: create or refine the design together with clients by using advanced design software.
• File Formats: work out 3D design file formats, including .DXF, .DWG, .STEP, .IGES, and .PDF.
• File Optimization: Optimize the design files for laser cutting, ensuring proper scaling, alignment, and layering.
3) Material Selection and Inspection
• Material Choice: choose the appropriate material based on client specific demand, considering factors like thickness, type, budget and quality.
• Inspection: Perform a thorough inspection of the material to ensure it meets manufacture grade and standards and is free from defects.
• Material preparation: clean and degrease the material for next production.
4) Machine Setup and Calibration
• Machine Configuration: set up the the laser cutting machine with correct parameters for the material and design, including power, speed, and focus adjustments.
• Calibration: Calibrate the laser cutting equipment to ensure precision and accuracy.
5) Cutting Process
• Loading Material: load material onto cutting bed of laser cutting machine.
• Cutting: Execute the cutting process, closely monitoring the machine and manufacture processing to ensure optimal performance and cutting correct result.
• Real-Time Adjustments: conduct real time adjustment to ensure cutting quality and precision.
6) Post-Cutting Inspection
• Visual Inspection: perform visual inspection to check for any defects or burrs.
• Dimensional Verification: check sizes to verify they meet the specified dimensions and tolerances.
• Edge Quality Check: Examine the edges for smoothness and no-burrs or marks.
14. What’re Affecting Pricing in Laser Cutting Services
If you consult with a laser cutting manufacturer for laser cutting quote, the following factors are the regular considerations that’ll be taken into account for cost calculation.
1) Material
Material types vary, different types and grades have different cost.
Also for same type material, its quality grade will impact cost too, higher grade will be more expensive.
2) Material Thickness
If two thicknesses can meet the demand, thicker material requires more time to cut, therefore higher cost.
3) Design Complexity
Some Intricate designs or completed patterns will require more time in cutting, tighter tolerances higher precision. These will increase cost.
On the other hand, simple design and patterns will needs less time, therefore, lower cost.
4) Cutting Speed and Power
Configuration of machine with higher speed and power will increase consume more power, thus more cost.
5) Batch Quantity of Parts
Bulk order quantity will typically affect unit cost, larger quantity will reduces unit cost.
6) Machine Setting-up and Programming Time
Custom design requires preparation time of setting up and programming. Standard or repeated orders will lower setting up time thus lower cost.
7) Post-Processing
If the parts needs post-processing, like de-burring, painting, anodizing, or assembly, that would increase cost too.
8) Turnaround Time
Rush order often carries an extra cost for rush services.
9) Labor involved
Skillful labor for setting up, programming, quality control will influence cost.
While manufacturer’s location and local wage level will also affect cost.
10) Waste and Yield
High waste of material will cause lower material use, as a result, higher cost.
Low material yield or high scrap rate will also increase cost.
Consider these factors when consulting for a project and have accurate estimating the cost of laser cutting, then have a better budget plan for project.
15. Images of Laser Cutting Parts at Batnon
16. Customer Testimonials
A fantastic metal working company, 10/10 customer service and fantastic value… I would highly recommend for custom motor prototype parts
Mr. Sean O’Brien
Manager Director
I LOVE the door openers. They look great and appear to be of high-quality. I have already told some of my friends about your company. Hopefully, they will also place orders with you. I look forward to doing business again. You were very responsive and professional. A real joy to work with.
Edward Zeidan
CEO
The parts were checked and are all good,I like the finish and packing over all good quality,we are happy with your work. Please convey it to your team.look forward in working with you in future also.
Cathal Barber
Owner
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