Introduction to Laser Cutting

Laser cutting is a versatile and precise method for cutting a wide variety of materials. Utilizing a focused laser beam, this technique can trim materials or create complex shapes that traditional drills and cutting tools struggle with. Apart from cutting, laser cutters can raster or etch designs onto workpieces by heating the surface and removing the top layer of the material, altering its appearance.

Laser cutters are invaluable tools in both prototyping and manufacturing. Hardware companies, start-ups, and makerspaces use them to create inexpensive, quick prototypes. For makers and hardware enthusiasts, laser cutters serve as a crucial digital fabrication tool, transforming digital designs into physical objects.

How Does Laser Cutting Work?

Laser cutting involves focusing a high-energy laser beam onto a material, which melts, burns, or vaporizes the material, leaving a clean edge. The laser beam is generated by stimulating lasing materials with electrical discharges or lamps within a closed container. This beam is then directed by mirrors or optical fibers to the cutting head, where it is focused onto the workpiece by a lens. The precise movement of the laser is controlled by a CNC system, following a programmed pattern to cut or engrave intricate designs​.

Types of Laser Cutters

CO2 Lasers

CO2 lasers are generated from electrically stimulated gas mixtures, primarily carbon dioxide. These are the most common type of laser cutters due to their efficiency, relatively low cost, and ability to cut through a wide range of materials.

• Common Uses: Wood, cardboard, leather, acrylic, glass, and some plastics.

Fiber Lasers

Fiber lasers utilize optical fibers doped with rare earth elements. They are known for their high precision and speed, making them ideal for cutting metals and other hard materials.

• Common Uses: Metals and other hard materials.

Neodymium Lasers

Neodymium lasers are formed from neodymium-doped crystals. These lasers have high intensity, allowing them to cut through much thicker materials compared to CO2 lasers.

• Common Uses: Metals, plastics, and ceramics.

Common Laser Cutting Materials

Laser cutters can handle a diverse array of materials, each with unique properties and applications:

1. Wood: Laser cutting wood produces clean edges and allows for intricate designs. However, it generates smoke and requires proper ventilation​.
2. Plastics: Acrylic and other plastics are commonly laser cut for signage and decorative items. Special care is needed to manage fumes and ensure a smooth finish​​.
3. Cardboard: Often used for prototyping and packaging, laser-cut cardboard is precise and efficient.
4. Metals: Laser cutting is excellent for metals like steel, aluminum, and brass, enabling precise and intricate cuts without physical contact​​.
5. Composites: These materials combine multiple substances to enhance properties and are used in specialized applications like aerospace and automotive parts.

What Materials Cannot Be Laser Cut

Certain materials are unsuitable for laser cutting due to the potential release of harmful fumes or the material’s physical properties: 

Organics

• Acceptable: Wood, plywood, paper, cardboard, cork, suede.
• Take Care: MDF, food products, fabrics, leather.
• Avoid: Flesh, pleather.

Plastics

All plastics emit some form of toxic fumes when cut with a laser, so full extraction systems are necessary.

• Acceptable: PMMA (acrylic), PES, POM, PP, PE.
• Take Care: PETG, PUR, polyimide, rubber, EPS, foams.
• Avoid: PVC, PTFE (Teflon), PC, ABS, HDPE, nylon.

Minerals and Metals

• Acceptable: Slate, pebbles, stone, marble, granite, soapstone, onyx, anodized aluminum, ceramics.
• Take Care: Glass, glass mirror, painted or coated metals.

Composites

Composites can release toxic fumes, so it’s crucial to handle them with care.

1. Take Care: Corian, magnetic sheet.
2. Avoid: Fiberglass, PCB (FR4), epoxy, coated carbon fibers.

Source: Laseruser

Safety and Precautions

Importance of Full Extraction for Plastics

When cutting plastics, it’s vital to use a full extraction system to remove toxic fumes and protect both the machine and the operator. Different plastics produce different types of harmful gases, so understanding these risks is crucial.

Risks Involved with Cutting Certain Materials

Materials like PVC and PTFE release particularly dangerous fumes that can damage the laser cutter and pose health risks. Additionally, synthetic materials like pleather and chrome-tanned leather should be avoided due to the toxic fumes they emit when cut.

Specific Material Safety Considerations

• Chrome-Tanned Leather: Releases toxic fumes and should be avoided.
• Vegetable-Tanned Leather: Considered safe for laser cutting.

Common Uses and Applications

Automotive Industry

Laser cutting is used to create car parts and components with tight tolerances and complex shapes, ensuring high precision and quality.

Medical Device Industry

The medical device industry benefits from laser cutting’s ability to produce intricate medical devices, such as pacemakers and stents, with clean, precise cuts.

Jewelry Industry

Laser cutting allows for detailed patterns and designs in metal and gemstones, enhancing creativity and precision in jewelry making.

Ceramic Manufacturing

In the ceramic industry, laser cutting is used to create precise shapes and decorative elements, improving both functionality and aesthetics.

Silicon Industry

The production of silicon wafers for electronic devices often involves laser cutting, which can create intricate patterns required for modern electronics.

Packaging Industry

Laser cutting is used to create packaging products, such as boxes and containers, providing precision and flexibility in design.

Metalworking Industry

Laser cutting shapes metal into desired forms for construction, automotive, and aerospace uses, ensuring high accuracy and efficiency.

Woodworking Industry

Laser cutting produces intricate wood designs for furniture, cabinets, and decorative items, offering unparalleled detail and precision.

Example Projects and Products

Snips Voice Interaction Base Kit

This product features laser-cut acrylic, demonstrating the utility of laser cutting in product design and its ability to create precise, clean components.

Combining Laser Cutting with Other Technologies

Laser cutting is often combined with other digital fabrication technologies, such as 3D printing, to achieve complex and innovative designs, offering ultimate design freedom.

Conclusion

Laser cutting is a powerful and versatile technology that plays a crucial role in various industries, from automotive to jewelry making. Its ability to cut and etch a wide range of materials with high precision and speed makes it an indispensable tool in modern manufacturing and prototyping. By understanding the different types of laser cutters, the materials they can handle, and the safety precautions necessary, users can fully leverage the potential of laser cutting to bring their digital designs into the physical world. As laser cutting technology continues to advance, its applications and capabilities will only expand, offering even greater possibilities for innovation and creativity.

There are many different methods that metal fabricators use to cut metal, but laser cutting is one of the most advanced techniques. A laser cutter’s ability to make precise cuts at speeds unmatched by other flat sheet cutting methods makes it one of the best sheet metal fabrication choices. There are several benefits to this method of cutting, including:

Competitive Pricing

Laser cutting is a highly automated process, making labor costs minimal when compared to hand-operated machinery. Since costs associated with sheet metal fabrication include labor, operation and machine expenses, this is an important factor to consider. The operating costs and machine costs are fairly average compared to other cutting techniques.

Generally, companies will find that outsourcing laser cutting for their sheet metal fabrication is the most effective option for most projects. Laser-cutting machines can be quite expensive, and most companies find that it is easier and less expensive to outsource this aspect of their fabrication process. 

One of the great things about laser cutters is that there are no dull or worn blades to worry about, making die changeovers a thing of the past. This also means that by placing larger orders, you can reduce costs tremendously, as the automated system does the mapping and planning for each additional piece. 

Although laser cutting isn’t the cheapest cutting technology available, it’s more than affordable for most projects. It has some major benefits over other cutting forms, such as water jet cutting or hand cutting processes.

Unrivaled Speed, Efficiency & Automation

A laser cutting machine can move as quickly as 1,000 holes per minute. Of course, the exact speed will vary depending on the tolerances and intricacy of the parts.

CNC controls typically run laser cutting. The formulas entered into the computer mean each part and product is identically fabricated, leading to fewer defects per batch.

Quality Precision

Laser cutting can create tiny cuts at tight tolerances. However, that’s the tradeoff: the more precision you want, the slower the laser will move. Yet, this highly detailed capability is unique to laser cutting. So, laser cutting is the only type of cutting that will get the job done well if you require intricate cuts.

Beyond that, all laser-cut edges and curves are smooth, sharp, and clean, which means there is very little, if any, burring because the laser melts rather than physically cuts the metal.

The only thing to consider is if your project requires very thick sheets of metal – thicker metals affect the cut’s quality, and a laser will leave some dross (melted metal scum) behind on thick metals. Aside from this dross, there is little to no clean-up involved in the majority of laser cutting projects.

Versatility

The combination of cost, speed, automation, and precision makes laser cutting a great choice for any size product or project. This makes many routine tasks/projects easy, including prototypes, industrial orders, delicate designs, and larger cutouts. Lasers are capable of making holes, slots, tabs, and other cut fabrications with no interruption of the cutting process. The incredible precision allows for tight tolerances on intricately detailed designs. If your project doesn’t require tight tolerances, the laser can move quickly and produce parts at incredible speeds. This makes laser cutting a fantastic choice for a wide spectrum of projects.

Yarbrough Industries is proud to offer laser cutting services for your next fabrication product. We can fabricate any order, whether it includes prototypes, components, or final assemblies. We adhere to the belief that high-quality results can only be achieved through the use of high-quality equipment. Laser cutting offers the ability to cut through various materials and thicknesses at high speeds, producing extremely precise and accurate cuts.