What Can A Laser Cutter Do? The Basics and What Materials Can Be Cut

Introduction

When it comes to manufacturing, choosing the right cutting technique is crucial for achieving the desired results in your projects. Whether you’re involved in rapid prototyping or full-scale production, the method you select will significantly impact the quality, speed, and cost of your operations. Two of the most popular cutting technologies in the industry are laser cutting and waterjet cutting. Each has its own set of strengths and weaknesses, making them suitable for different applications.

In this article, we’ll explore the fundamental differences between laser cutting and waterjet cutting, analyze their advantages and disadvantages, and help you determine which method is best suited for your specific needs.

How Each Process Works

Laser Cutting

Laser cutting is a subtractive manufacturing process that uses a high-powered laser beam to cut through or engrave materials. The process involves focusing a laser—essentially a concentrated beam of light—onto a small area of the material. The energy from the laser heats the material to the point where it either melts or vaporizes, creating a precise cut.

This technology is incredibly versatile and can be used on a wide range of materials, including metals like stainless steel, aluminum, and mild steel, as well as non-metals such as plastics, glass, and wood. Laser cutting is particularly well-suited for projects requiring high precision, as the laser beam can achieve a cutting slit size as small as 0.006 inches (0.15 mm).

Learn more about Lazer Cutting here: “What Can A Laser Cutter Do? The Basics and What Materials Can Be Cut”

Waterjet Cutting

Waterjet cutting is a process that uses a high-pressure jet of water to cut materials. The water is often mixed with an abrasive material, such as garnet, to enhance its cutting ability. The waterjet is focused through a small nozzle, where it is expelled at pressures as high as 60,000 pounds per square inch (psi). This high-pressure stream of water physically erodes the material along the cut line, effectively slicing through it without generating heat.

Waterjet cutting is known for its versatility in cutting a wide variety of materials, including metals, stone, tile, rubber, foam, and cloth. Because it does not rely on heat, waterjet cutting is ideal for materials that are sensitive to high temperatures, such as plastics and composites. Additionally, it can cut much thicker materials than laser cutting, with optimal thicknesses ranging from 0.4 to 2.0 inches (10 to 50 mm).

Key Comparisons Between Laser Cutting and Waterjet Cutting

Material Capabilities

When deciding between laser cutting and waterjet cutting, one of the most critical factors to consider is the type of material you need to cut.

Laser Cutting

Laser cutting is incredibly versatile when it comes to materials. It is particularly effective on non-metals such as wood, acrylic, glass, and various plastics. However, laser cutting can also be used on metals like stainless steel, aluminum, and mild steel. The primary limitation of laser cutting is its struggle with materials that have different melting points or are reflective. For example, cutting highly reflective materials such as copper can be challenging because the laser beam is reflected away from the material, reducing its effectiveness.

Waterjet Cutting

Waterjet cutting has virtually no material restrictions. It can cut through almost any material, including metals, composites, stone, and even food products. Because it uses mechanical erosion rather than heat, waterjet cutting is ideal for materials that would otherwise be damaged by the high temperatures associated with laser cutting. Additionally, waterjet cutting excels at slicing through thicker materials, making it the preferred choice for projects involving thick metal plates or stone slabs.

Precision and Tolerance

Precision is another critical consideration when choosing between laser cutting and waterjet cutting.

Laser Cutting

Laser cutting offers superior precision, with a minimum cutting slit size of 0.006 inches (0.15 mm) and a processing tolerance of approximately 0.002 inches (0.05 mm). This high level of precision makes laser cutting the go-to choice for intricate designs, detailed engravings, and projects where tight tolerances are essential. The laser’s ability to create fine, clean cuts also means that less post-processing is required, further enhancing its appeal for precision work.

Waterjet Cutting

Waterjet cutting is also precise, but it does not match the fine tolerances of laser cutting. The minimum cutting slit size for waterjet cutting is around 0.02 inches (0.5 mm), and its processing tolerance is about 0.008 inches (0.2 mm). While this level of precision is more than adequate for many applications, it may not be sufficient for projects requiring extremely detailed cuts or tight dimensional tolerances.

Speed and Efficiency

The speed at which materials can be cut is another key factor that influences the choice between laser cutting and waterjet cutting.

Laser Cutting

Laser cutting is generally faster, especially when working with thinner materials. Cutting speeds can range from 20 to 70 inches per minute, depending on the material and thickness. This speed advantage makes laser cutting particularly well-suited for high-volume production environments where time is of the essence. The quick processing time also means that laser cutting is more efficient in terms of machine utilization, which can translate to lower overall costs for large-scale projects.

Waterjet Cutting

While slower than laser cutting, waterjet cutting offers other advantages that may outweigh its speed limitations. Waterjet cutting speeds typically range from 1 to 20 inches per minute, depending on the material and thickness. While this slower speed might be a drawback in high-volume production settings, it is often acceptable for low-volume, high-mix environments where the ability to cut a wide variety of materials is more important than sheer speed.

Potential Material Damage

The potential for material damage is an important consideration, particularly for projects involving delicate or heat-sensitive materials.

Laser Cutting

Laser cutting can cause burn marks and discoloration on certain materials due to the high temperatures involved in the process. These burn marks can often be removed through post-processing, but this adds an extra step to the manufacturing process. Additionally, the heat generated by the laser can create a heat-affected zone (HAZ) around the cut, which may weaken the material or cause it to deform.

Waterjet Cutting

Waterjet cutting is a cold-cutting process that does not generate any heat. As a result, there is no heat-affected zone, making waterjet cutting ideal for materials that would be damaged or weakened by high temperatures. However, the high-pressure waterjet can apply significant force to the material, which can cause small parts to deform or even fail to cut properly. This is particularly true for thin or delicate materials, where the force of the waterjet may be too much for the material to withstand.

Advantages and Disadvantages

Laser Cutting Advantages

High Precision and Accuracy: Laser cutting is known for its exceptional precision, making it the preferred choice for projects that require detailed designs and tight tolerances.
Speed: Laser cutting is much faster than waterjet cutting, especially when working with thinner materials. This makes it ideal for high-volume production environments.
Minimal Waste and Clean-up: Since laser cutting uses light to cut materials, there is very little physical waste produced, and any dust can be easily vacuumed.
Engraving Capabilities: Laser cutting can also be used for engraving, allowing for the addition of serial numbers, assembly marks, or aesthetic designs directly onto the material.

Laser Cutting Disadvantages

Limited Thickness: Laser cutting is generally limited to materials up to 1 inch thick. While it can cut thicker materials, the process becomes less efficient, and the quality of the cut may suffer.
Potential for Hazardous Fumes: Depending on the material being cut, laser cutting can produce fumes that may be hazardous if not properly ventilated.
Thermal Stress: The heat generated during laser cutting can cause thermal stress in the material, potentially leading to cracks or warping.

Waterjet Cutting Advantages

Versatility: Waterjet cutting can be used on a wide range of materials, including those that are difficult or impossible to cut with lasers.
No Heat-Affected Zone: Because waterjet cutting is a cold process, there is no risk of thermal damage to the material, making it ideal for heat-sensitive materials.
Ability to Cut Thick Materials: Waterjet cutting excels at cutting thicker materials, with optimal thicknesses ranging from 0.4 to 2.0 inches.
Clean and Smooth Cuts: Waterjet cutting produces clean, smooth edges that typically do not require additional finishing.

Waterjet Cutting Disadvantages

Lower Precision: While still precise, waterjet cutting does not offer the same level of accuracy as laser cutting, which may be a drawback for projects requiring very tight tolerances.
Slower Cutting Speeds: Waterjet cutting is generally slower than laser cutting, which can increase production time and costs.
High Noise Levels and Clean-up: Waterjet cutting is noisy and requires significant clean-up due to the mixture of water and abrasives used in the process.

Application Scenarios

When to Use Laser Cutting

Laser cutting is the ideal choice for projects that require high precision and intricate designs. It is also the preferred method when speed is a critical factor, such as in high-volume production environments. Additionally, laser cutting is well-suited for applications that require engraving, as it can easily add serial numbers, assembly marks, or decorative elements directly onto the material.

Laser cutting is particularly effective for materials less than 1 inch thick, such as thin sheet metal, acrylics, and other non-metals. It is also the best option when you need to achieve a polished edge, such as when cutting acrylic for display cases or signage.

When to Use Waterjet Cutting

Waterjet cutting is the better choice for projects involving thick materials or a variety of material types. It is especially useful for cutting materials that are sensitive to heat, such as composites, plastics, and certain metals. Because waterjet cutting does not generate heat, there is no risk of thermal damage, making it the preferred method for materials that could be weakened or deformed by high temperatures.

Waterjet cutting is also ideal for projects where versatility is important. If you need to cut a wide range of materials, from metal to stone to rubber, waterjet cutting offers the flexibility to handle them all with ease.

Cost Considerations

Operating Costs

When evaluating the cost of laser cutting versus waterjet cutting, it’s important to consider both the initial investment and the ongoing operating costs.

Laser Cutting

Laser cutting typically involves a higher initial investment, particularly for fiber laser systems, which are more expensive than their CO2 counterparts. However, laser cutting is generally cheaper to operate, with costs ranging from $2 to $3 per hour. This lower operating cost is due to the minimal consumables required—primarily electricity and occasional replacement of the laser optics.

Waterjet Cutting

Waterjet cutting, on the other hand, has higher operating costs, typically ranging from $50 to $75 per hour. This is due to the need for abrasive materials, such as garnet, and the maintenance required for the high-pressure pumps. While the initial investment in a waterjet system may be lower, the ongoing costs can add up, particularly for high-volume operations.

Maintenance and Training

Laser Cutting

Laser cutting systems, particularly modern fiber lasers, require skilled operators to achieve optimal performance. However, advancements in technology have made these systems easier to manage, with intuitive interfaces and automated settings that reduce the need for constant operator intervention. Maintenance for laser systems is relatively low, primarily involving the cleaning or replacement of optics and regular system checks.

Waterjet Cutting

Waterjet cutting systems are generally easier to operate, requiring less specialized training. The maintenance, however, is more frequent and involves tasks such as rebuilding the high-pressure pumps and replacing worn nozzles. While these tasks are straightforward, they need to be performed regularly to keep the system running efficiently.

Technological Advancements and Trends

Laser Cutting Advancements

Recent advancements in laser cutting technology have significantly expanded its capabilities. Higher-wattage fiber lasers, such as those offered by Amada’s ENSIS and VENTIS systems, now allow for the cutting of thicker materials, including aluminum up to 1 inch thick. These advancements have made laser cutting increasingly competitive with waterjet cutting for a broader range of applications.

In addition to power increases, modern laser systems feature beam shaping technologies that enhance cutting quality and speed. For example, the VENTIS system uses a dynamic beam that moves within the nozzle, allowing for smooth cuts and reduced striations on thicker materials.

Waterjet Cutting Innovations

Waterjet cutting has also seen significant innovations, particularly in the development of minijet and microjet technologies. These advancements allow for high-precision cutting, making waterjet systems more suitable for intricate applications that were previously the domain of laser cutting.

Another trend in waterjet cutting is the creation of extensive material libraries, allowing operators to easily switch between different materials with just a few clicks. This flexibility is particularly valuable in industries that work with a wide range of materials, such as aerospace or automotive manufacturing.

Conclusion

In the debate between laser cutting and waterjet cutting, the right choice depends on the specific needs of your project. Laser cutting excels in precision, speed, and the ability to engrave, making it ideal for detailed work on thinner materials. Waterjet cutting, on the other hand, offers unmatched versatility in material selection and thickness, making it the better option for projects involving a wide range of materials or thick sheets.

For many businesses, the best approach is to use both technologies in a complementary fashion. By leveraging the strengths of each method, you can maximize your production capabilities, bid on a wider variety of projects, and ensure that you always have the right tool for the job.

Additional Resources

For more information on laser cutting and waterjet cutting, consider checking out our services and videos on social media. If you’re ready to start your project, visit our website to learn more or to request a free laser cutting or waterjet cutting quote.

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What Can A Laser Cutter Do? The Basics and What Materials Can Be Cut

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:

Wood: Laser cutting wood produces clean edges and allows for intricate designs. However, it generates smoke and requires proper ventilation.
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.
Cardboard: Often used for prototyping and packaging, laser-cut cardboard is precise and efficient.
Metals: Laser cutting is excellent for metals like steel, aluminum, and brass, enabling precise and intricate cuts without physical contact.
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.

Take Care: Corian, magnetic sheet.
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.

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Sheet metal fabrication is a cornerstone of modern manufacturing, crucial to various industries from automotive to aerospace. This intricate process transforms flat sheets of metal into diverse shapes and structures, utilizing specialized tools and techniques.

The Basics of Sheet Metal Fabrication

Sheet metal fabrication is the process of forming, cutting, and assembling metal sheets into functional products. It involves several stages including cutting, bending, and joining. The versatility of sheet metal allows for the creation of a wide range of products, from small components to large structures.

The Sheet Metal Fabrication Process

Design and Prototyping

The journey begins with design and prototyping. Engineers use CAD (Computer-Aided Design) software such as Solidworks or Catia to create detailed blueprints and technical drawings. This ensures precision and feasibility before moving to production.

Cutting Techniques

Cutting is the first major step in the fabrication process. Various cutting methods are employed depending on the material and required precision:

Laser Cutting: Utilizes a high-powered laser to melt and vaporize the metal, offering high precision and clean edges. It’s ideal for intricate designs and tight tolerances.
Waterjet Cutting: Uses a high-pressure stream of water mixed with an abrasive substance to cut through metal. This method is versatile and can handle various materials and thicknesses without introducing heat, which can distort the material.
Plasma Cutting: Involves ionized gas to heat and cut through the metal. It’s faster than other methods and suitable for thicker materials, though it may introduce some heat-affected zones.

Forming and Bending

Once cut, the metal is formed and bent into shape. This is achieved through several methods:

Brake Pressing: A manual process using a clamping bar and plate to bend the metal, suitable for small-scale production and prototyping.
Roll Bending: Similar to brake pressing but used to create cylindrical or conical shapes.
Press Brake Bending: Utilizes hydraulic machines with punches and dies for precision bending, suitable for sheets up to 6mm thick.

Joining Techniques

Assembling the cut and formed metal pieces into a final product involves various joining methods:

Fasteners: Includes screws, rivets, and bolts which provide secure and removable connections.
Welding: Melts the metal surfaces to fuse them together, creating strong, permanent bonds. Common welding techniques include MIG, TIG, and spot welding.
Adhesive Bonding: Uses specialized adhesives to join parts, offering weight reduction and improved aesthetics.

Finishing Techniques

Finishing enhances the appearance, durability, and functionality of the final product:

Painting: Provides a protective layer and allows for customization through various colors and finishes.
Powder Coating: Involves applying a dry powder that is cured to form a durable, attractive finish.
Anodizing: An electrochemical process that creates a protective oxide layer on the metal surface, enhancing corrosion resistance and providing a decorative finish.

Types of Sheet Metal

Sheet metal comes in various types, each with unique properties suited to different applications:

Steel: Known for its strength and durability, it is commonly used in construction and automotive industries.
Aluminum: Lightweight and corrosion-resistant, ideal for aerospace and marine applications.
Stainless Steel: Offers excellent resistance to corrosion and staining, used in kitchen appliances and medical devices.
Copper: Valued for its excellent electrical conductivity, it is commonly used in electrical and roofing applications.

Common Applications of Sheet Metal Fabrication

Sheet metal fabrication finds its place in countless applications across various industries. Here are some of the most common uses:

Automotive Industry

Sheet metal is extensively used in the automotive industry to create body panels, chassis, and other structural components. Its durability and formability make it an ideal material for this purpose.

Aerospace Industry

In the aerospace sector, sheet metal is used to manufacture aircraft components, including fuselage panels, wings, and engine parts. The lightweight nature of materials like aluminum is particularly advantageous here.

Construction Industry

From HVAC systems to roofing and structural components, sheet metal plays a crucial role in the construction industry. Its versatility and strength are key factors in its widespread use.

Electronics and Electrical Industry

Sheet metal is used to create enclosures, brackets, and other components in the electronics and electrical industry. Copper, in particular, is prized for its excellent conductivity.

Benefits and Limitations of Sheet Metal Fabrication

Sheet metal fabrication offers numerous benefits but also comes with some limitations.

Benefits

Versatility: Sheet metal can be cut, bent, and shaped into virtually any form.
Durability: Products made from sheet metal are often strong and long-lasting.
Precision: Advanced tools and techniques allow for high levels of accuracy.

Limitations

Cost: The initial setup and tooling can be expensive.
Complexity: Some designs may be challenging to achieve.
Material Limitations: Not all metals are suitable for all applications.

Key Tools in Sheet Metal Fabrication

Various tools are used in the sheet metal fabrication process, each serving a specific purpose. Key tools include:

Press Brakes

Used for bending sheet metal into precise angles, press brakes are essential for creating complex shapes.

Shears

These tools are used for cutting sheet metal into smaller pieces. They come in various forms, from manual to hydraulic shears.

Laser Cutters

Laser cutters offer high precision and can cut through various thicknesses of sheet metal with ease.

Welding Equipment

Welding equipment is used to join pieces of metal together. Various welding techniques, such as MIG, TIG, and spot welding, are employed depending on the material and application.

Conclusion

Sheet metal fabrication is a dynamic and essential process in modern manufacturing. Combining precision, versatility, and strength, it enables the production of a wide range of products used in diverse industries. Understanding the intricacies of this process is crucial for anyone involved in manufacturing and engineering. By mastering the techniques and tools of sheet metal fabrication, manufacturers can continue to innovate and create high-quality products that meet the evolving needs of various sectors.

For more detailed information on sheet metal fabrication, refer to our website or contact us below.

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Metal fabrication is a comprehensive process that involves transforming raw metal materials into finished products. This process includes several techniques such as cutting, bending, and assembling, and is essential across various industries. Understanding the nuances of metal fabrication can help appreciate its significance in modern manufacturing and construction.

As the backbone of manufacturing and construction, metal fabrication’s significance cannot be overstated. This process ensures that structures are safe, durable, and capable of withstanding various stresses and environmental conditions. From towering skyscrapers to delicate medical devices, the precision and expertise involved in metal fabrication are what bring these structures to life.

Understanding Metal Fabrication

Metal Fabrication Definition: Metal fabrication is the act of constructing machines and structures from raw metal materials. This process encompasses various techniques including cutting, bending, and assembling, often facilitated by advanced machinery and skilled labor.

Types of Metal Fabrication Processes

Cutting: This fundamental process involves slicing metal sheets into desired shapes and sizes. Traditional methods like sawing have evolved into modern techniques such as laser cutting, waterjet cutting, and plasma arc cutting, which offer precision and efficiency.
Drawing: Drawing involves pulling metal through a die to reduce its diameter, often used to create wires. This can be done at room temperature (cold drawing) or at elevated temperatures to ease the process.
Folding: Folding manipulates metal to bend at specific angles, commonly using a brake press. This process is crucial for shaping sheet metal into desired forms.
Forging: One of the oldest fabrication techniques, forging shapes metal using compressive forces. This can be done at various temperatures, including cold, warm, and hot forging, depending on the metal and desired properties.
Extrusion: This process forces metal through a die to create objects with a fixed cross-sectional profile, such as pipes and tubes. Extrusion can be performed hot or cold, each method suited to different metals and end uses.
Casting: Metal casting involves pouring molten metal into a mold to achieve a specific shape. This versatile process is ideal for creating complex geometries and is widely used in manufacturing.
Welding: Welding joins two metal pieces by melting their edges and fusing them together. Various welding techniques, such as arc welding and gas tungsten arc welding, are employed based on the material and application.
Stamping: Stamping involves placing metal sheets between dies and applying high pressure to shape the metal. This process combines punching, bending, and other operations to form parts with precision.

Each of these processes plays a crucial role in metal fabrication. Cutting is often the first step, creating manageable pieces from large sheets or bars of metal. Bending follows, shaping these pieces into forms that can be assembled into more complex structures. Welding ensures these parts are securely joined, while machining refines the shapes and dimensions. Finally, assembling brings all the parts together into a cohesive whole.

Structural Metal Fabrication

Structural metal fabrication focuses on creating components for buildings and other large structures. This includes beams, columns, and girders that form the backbone of construction projects. The strength and durability of these fabricated pieces are crucial for the safety and integrity of the structures they support.

In structural metal fabrication, precision and strength are paramount. Beams and columns must be capable of supporting immense loads, often under challenging conditions. The fabrication process involves stringent quality control measures to ensure that every piece meets the necessary standards. This includes rigorous testing for strength, durability, and resistance to environmental factors such as corrosion.

Commercial Metal Fabrication

Commercial metal fabrication involves producing metal parts and products for various commercial applications. This can range from retail fixtures and furniture to components used in the service industry. Precision and quality are paramount in commercial metal fabrication, ensuring that the final products meet the required standards and specifications.

In commercial applications, aesthetics can be as important as functionality. Retail fixtures, for example, must not only be sturdy and functional but also visually appealing. This demands a high level of craftsmanship and attention to detail in the fabrication process. Additionally, commercial metal products often need to meet specific regulatory standards, requiring meticulous documentation and quality control.

Custom Metal Fabrication

Custom metal fabrication is tailored to meet specific needs and requirements. It involves creating unique metal parts and structures that are not available off the shelf. This process is highly flexible, allowing for a wide range of designs and applications. Custom metal fabrication is often used in specialized industries where standard components won’t suffice.

The customization process begins with a detailed design phase, where engineers and designers collaborate to create bespoke solutions. This might involve unique shapes, sizes, or materials to meet specific requirements. Custom fabrication often employs advanced techniques such as CNC machining or 3D printing to achieve the desired results. This approach allows for a high degree of precision and flexibility, catering to unique and complex needs.

How Different Metals Are Fabricated

Different metals require different fabrication techniques. For example, steel is often cut with plasma or laser cutters, while aluminum may be machined or bent using specific tools to avoid cracking. Understanding the properties of each metal is crucial for selecting the appropriate fabrication methods.

Steel, known for its strength and durability, is a staple in construction and manufacturing. Its fabrication often involves high-temperature processes like welding and plasma cutting. Aluminum, on the other hand, is lighter and more malleable, making it suitable for applications where weight is a concern. Fabricating aluminum requires lower temperatures to prevent warping and cracking, and it is often machined to precise specifications.

How Does Custom Metal Fabrication Work?

Custom metal fabrication begins with a detailed design phase, where engineers and designers work together to create precise plans and specifications. These designs are then translated into physical products using various fabrication techniques. The process often involves iterative testing and adjustments to ensure the final product meets all requirements.

The initial design phase is critical, involving detailed discussions and planning to ensure that the final product meets the client’s needs. Advanced software tools are often used to create detailed models and simulations. Once the design is finalized, the fabrication process begins, using techniques like CNC machining, laser cutting, and welding. Throughout the process, quality control measures are implemented to ensure the final product meets all specifications.

Why You Should Outsource Metal Fabrication

Outsourcing metal fabrication can offer several advantages. Specialized fabrication companies have the expertise, equipment, and resources to handle complex projects efficiently. This can lead to cost savings, higher quality products, and faster turnaround times. Additionally, outsourcing allows businesses to focus on their core competencies while leaving the fabrication work to the experts.

By outsourcing metal fabrication, businesses can leverage the expertise and advanced equipment of specialized firms. This can lead to significant cost savings, as there is no need to invest in expensive machinery or training. Moreover, specialized fabricators often have established quality control processes, ensuring that the final products meet all necessary standards. This approach also allows businesses to focus on their core operations, improving overall efficiency and productivity.

Techniques in Metal Fabrication

Metal fabrication employs a variety of techniques to achieve precise results. Some advanced methods include:

Laser Cutting: Provides high precision and is ideal for intricate designs.
CNC Machining: Uses computer numerical control to automate the fabrication process, ensuring accuracy and efficiency.
Water Jet Cutting: Uses high-pressure water mixed with abrasive materials to cut metal without generating heat.

Industries Relying on Metal Fabrication

Numerous industries depend on metal fabrication for their operations. These include:

Construction: For beams, columns, and other structural components.
Automotive: For frames, body parts, and engine components.
Aerospace: For aircraft frames, landing gear, and other critical parts.
Manufacturing: For machinery, tools, and equipment.

The Evolution of Metal Fabrication

Metal fabrication has evolved significantly over the years. From ancient blacksmithing techniques to modern CNC machining, the field has continually adapted to new technologies and materials. Today’s fabricators use advanced software and machinery to achieve unprecedented levels of precision and efficiency.

The evolution of metal fabrication is marked by significant technological advancements. Ancient blacksmiths used hammers and anvils to shape metal, relying on skill and experience. The industrial revolution brought about new machinery and techniques, such as steam hammers and rolling mills. In the modern era, digital technology has revolutionized the field. CNC (Computer Numerical Control) machines and CAD (Computer-Aided Design) software allow for precise control and complex designs, transforming metal fabrication into a high-tech industry.

Conclusion

Metal fabrication is a dynamic and indispensable part of modern industry. From the towering skyscrapers that define our cities to the intricate components that power our technology, the impact of metal fabrication is all around us. Understanding this process not only highlights its importance but also underscores the remarkable skills and technologies that make it possible. Whether you’re in construction, manufacturing, or any other industry, metal fabrication is a cornerstone of progress and innovation.

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how is powder coating important in metal fabrication?

Metal fabricators are a pillar that supports the nation’s infrastructure and economy. Countless aspects of our day-to-day life depends on some form of product fabricated from metal, whether its household appliances or critical medical technology. In short, fabricated metal products are invaluable in society, if they’ve been properly finished by a trained professional.

Why is Metal Finishing Important?

Taken on its own, raw metal has some distinct problems; without proper finishing, exposed metals can eventually corrode and tarnish. Depending on the intended use, unfinished metal-fabricated parts can be eroded by salts, weakened by ultraviolet light or rusted by rain. However, the metal fabrication industry realized many years ago that properly finishing components is essential for enhancing durability and the product’s life span.

Beyond that, correctly finishing metal-fabricated products greatly enhances aesthetics, which in turn, makes the products more valuable and pleasing to the end-user. In other words, metal finishing done right is a win for both the metal fabricator and the customer.

Powder Coating’s Impact on Fabrication

Metal fabricators didn’t always have powder coating as an option, though. In the past, fabricators opted for liquid paint; yet, this process took time, required proper conditions and performed poorly unless professionally applied.

In the 1960s, scientists perfected powder-coating, which was a new finishing process that revolutionized the metal product industry. Powder coating provided immediate advantages over previous finishing methods, giving metal fabricators and product manufacturers a leading edge.

Powder coating improves durability, while offering a premium appearance and lowering environmental impact. Over the years, powder coating has allowed metal fabricators to improve production time while increasing functional protective product properties.

How Does Powder Coating Work?

It’s crucial to understand exactly how powder coating works to fully appreciate its unique advantages. While conventional liquid paint has color pigments suspended in liquid, powder coating operates in a completely dry environment— this is an important aspect in finishing custom fabrication and coatings done through powder coating.

Here’s a brief overview of how powder coating works: dry powder receives a positive electric charge and gets sprayed under pressure to the unfinished metal object that’s grounded with a negative charge. This, in turn, creates an electrochemical change allowing molecules from the powder to attach to the metal. There’s a wide variety of powder bases including acrylic, polyester, epoxy, polyurethane or a blend of the aforementioned. The electric polarization inherent to the process allows entirely uniform coating without runs or sags.

After the fabricated metal parts have a uniform powder coating, they’re then placed in a high-temperature environment— the duration will ultimately depend on powder materials, and temperatures can range up to 400 degrees Fahrenheit. Powder-coated products are fully cured when they’re removed from the oven and can be used immediately.

Powder coating allows for complex geometric shapes to be easily coated with uniform coverage. Upon completion, powder-coated pieces have a solid, molecularly-dense, protective outer layer.

Unique Benefits of Powder Coating

Powder coating finish has a multitude of benefits over other available finishing options. Powder coating, performed by a professional, makes finished surfaces resistant to scratching, fading, wearing, and chipping. Beyond that, powder-coated metal products won’t corrode or rust, maintaining a new appearance throughout the product lifecycle. Powder coating also helps to make products nearly maintenance-free under normal usage, as there isn’t a need for repainting.

Powder-coated metal finishes stack up well when compared to other finish techniques. Since powder coating uses less equipment, requires less application time and takes up fewer raw materials, it’s a less expensive process than alternatives like plating and conventional painting. Powder coating is indeed a reliable process, reducing the amount of rejected work. It’s a cleaner, smoother and superior process than other finishing methods. Powder coating is environmentally-friendly, safe and cost-effective finishing. It’s no surprise that powder coating has such a superior advantage in the metal finishing industry.

It’s crucial to do your research when choosing a metal fabrication expert, as not all companies are capable of completing the same quality of work. Yarbrough Industries has years of experience here in Springfield, honing our skills across the board to deliver a quality product and measurable bottom-line value to our customers.

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Laser Cutting For Sheet Metal Fabrication

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.

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Metal Fabrication Basics

Metal fabrication is a small part of the metal manufacturing industry. There are many different types of manufacturing processes, including:

Forging
Smelting
Blacksmithing
Casting
Stamping
Painting
Roll Forming
Heat Treating
Structural Fabrication
Machining
Metal Fabrication

As you can imagine, the wide variety involved in metal manufacturing can be overwhelming. Metal fabrication, by itself, has many subcategories and niches that would be impossible to comprehensively list. Some different categories of metal fabrication you might encounter are heavy industrial plate metal, light industrial sheet metal, heavy structural steel, and light structural steel fabrication.

Heavy Industrial Plate Metal Fabrication

This type of fabrication might include enormous plate steel, sometimes 1”-4” thick (even heavier) and fabrication processes like plasma cutting, rolling, welding, heat treating, and finishing. Finished products that involve heavy industrial plate metal fabrication might include mining equipment, pressure vessels, and tanks.

Light Industrial Sheet Metal Fabrication

This type could include smaller weighted metal-like materials ranging from 1/32” – 1/2” and fabrication processes like Laser Cutting, Brake Forming, Welding, Anodizing, and Painting. The products produced using this type of fabrication might be Computer Enclosures, Cases, and OEM Parts.

Heavy Structural Steel Fabrication

These fabrication processes are done with sawing cutting, plasma cutting, drilling, welding, sandblasting, and painting. This process deals with structural iron and beams that weigh several hundred pounds or more per foot. You can see the results of heavy structural steel fabrication, check out skyscrapers, large bridges and tunnel supports.

Light Structural Steel Fabrication

This can include structural tube, angle and beams that weigh less than a hundred pounds per foot. Fabrication processes would typically be similar to heavy structural steel processes, but the products created would be Small Buildings, Small Bridges, Platforms, and Supports.

Metal Fabrication Versus Machining

Metal fabrication is a term that typically refers to manufacturing that includes cutting, forming, rolling, sawing and welding metal. However, it is not to be confused with machining. There is a bit of crossover with the two, but machining usually includes more detailed work such as milling, lathing, routing, and polishing and is typically a part of the manufacturing industry.

In addition, fabrication usually works with manufacturing tolerances at .010” – .030” whereas machining works with tolerances all the way down to .005” (and even smaller in many cases).

Advancements in Metal Fabrication

Metal fabrication, like all manufacturing industries, has transformed over the years as technology has become more advanced. This began with the Computer Numerically Controlled, CNC, machines. These types of machines, combined with Computer Aided Drafting, CAD, revolutionized the metal fabrication industry.

Prior to the invention of CNC and CAD, hand layouts and calculator math were the tools used by craftsmen to layout and calculate fabricated parts. Machines had manual gauges that would be fine-tuned by hand as the technician moved stops, dialed back gauges and tweaked settings.

However, those days are long gone and programs are now generated automatically from CAD drawings and sent, via computer and code, directly to the various machines. Lasers can cut metal like butter, brake forming machines can tell you which order to sequence your bends and robotic welders can weld endless amounts of wire throughout the night. Metal fabrication is still an enormous part of everyday life and most of us see it, or use it, without even knowing as much. Light rail transit cars, automobiles, snowblowers, electrical panels, guardrails, signs, etc. Metal fabrication is everywhere!

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Why You Should Hire A Local Machine Shop

When you need to hire a machine shop, it’s important to work with someone you can trust to get the job done right the first time. Working with a local company makes this much more likely. But why?

A local machine shop offers several advantages. When you are weighing your options, consider the following benefits of working with someone in your own backyard and what you should look for when doing so:

- You can be more specific: Clear communication and detailed specifics are essential to getting the end result you desire. Being able to deliver this information in person allows you to make sure your parameters are accurately conveyed and your machine shop understands exactly what you need. You can specify the tolerances needed and work with the local company to achieve accurate measurements and optimal results.
- You can make roughness smooth: An important aspect of your project is determining the desired roughness of the surface. Do you want smooth components, with a very polished surface? This depends greatly on the functionality of the parts. A local professional can explain how the roughness will affect the performance of your equipment and work with you to decide what roughness is best for your project.
- You can choose wisely: The materials you use for your manufacturing affect the final durability and performance. It also greatly affects the cost of production. Your local machine shop will review your options with you and let you personally examine various materials to determine which is best. You may even be able to look at similar products the shop has made in the past to make an informed comparison.
- You can enjoy savings: A local shop can save you both time and money. Enjoy a smaller budget by saving on delivery costs. Complete your project faster by cutting out delivery wait times. By working with someone local, you won’t be wondering where your parts are in transit or when the project will be completed.
- You can be involved: When you work with a local machine shop, you can be actively involved in the manufacturing process. This will provide peace of mind and a better overall experience with production.
- You can complete the process: Once the machine shop has designed and manufactured your piece, they can also install it. It is typically easier for the same professionals who created the part to also perform the installation. Working with someone local makes this possible.
- You can help your community: Obviously, we all want to do what we can to ensure that the community we live in is becoming better every year. Working with a local business helps your own community and you know that they will provide reliable, timely service to keep their reputation spotless.

Shop local with Yarbrough Industries! You’ll enjoy the advantages of working with a local machine shop right here in the heart of the Ozarks while receiving the best quality from some of the top professionals in the industry. Reach out to us today with any questions or to get started on your next project.

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Saving Money On Metal Fabrication

In every area of life, we are all looking for ways to save money, cut costs, and squeeze out every penny when it comes to our budget. No matter if it’s a trip to the grocery store, buying a car, or looking to repurpose an abandoned warehouse for something new, we all want the best quality at the best price possible. There are situations where the best price isn’t necessarily the lowest, but knowing the difference will give you the confidence you need to make an informed decision.

This is especially true when it comes to metal fabrication. Although there may not be coupons or weekly ads to compare prices, when you begin getting the bids for a job, it becomes a heavy task to sift through the facts and figures to try to ensure you are hiring the right fabricator or welder for the job. Every job has many different factors that have to be considered, but typically the bid’s total dollar amount is one of the most things you can look at.

When you are getting ready to request bids on an upcoming project, here are a few tips that can help keep estimates low and lead times short. Keep in mind, these are suggestions and you can alter each of them to fit your specifications and needs at any particular time.

Provide shop-ready drawings.

By providing your own drawings, you can eliminate the engineering process that many fabrication companies spend additional money on while forming their estimated bid.

Provide a completion date.

Every fabrication company has a different workload based on multiple factors. This means that your desired delivery date will impact their bid price and ability to fit the project into their schedule.

Provide addresses and contacts.

It is not uncommon for fabricators to do a majority of the work on-site, which can help shorten lead times considerably. By having this information upfront, you allow each metal shop to determine a closer estimate of their costs based on the specifications of the job site.

Provide load specifications if possible.

These include specs for tension, environmental loads, equipment limitations or restrictions, or even equipment cut sheets. This can provide them with valuable information on how they will be pricing your bid and if they will need to custom order anything.

Provide engineering drawings

Provide engineering drawings or basic arrangement drawings if possible. Once again, these small things allow estimators to have a clearer picture of the project in its entirety. That enables them to provide a more realistic bid total. Plus, their bid total won’t need to include costs related to this prep work.

Provide any plans and profiles available.

To reiterate for the third time, the more information you can provide prior to getting the bid, the more realistic and accurate that bid will be.

If you are ever in doubt about what you should provide, always err on the side of too much. Communication is key to more precise bids and the more detail you include, the closer to a factual total you will end up with. As an interested customer, the more information you can provide upfront, the better.

Another thing it is important to remember when you are considering a fabrication job is that if you need to make any major changes to these pre-stated specifications AFTER a job begins, it can extend the completion date out beyond the deadline and tack on extra costs that weren’t accounted for in the contingency figures. By being prepared in advance and knowing what you want from the start, your metal fabricator can actually get to work and complete the project as efficiently as possible.

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What Are Welding Procedure Specifications And Why Are They Important?

High-quality welds are the best way to ensure a successful metal fabrication project. Every single weld is important as they build on each other to ensure the final product’s structural integrity and longevity. Without sufficient welding quality control, mistakes can compromise the entire custom metal fabrication.

There are many ways that welding mistakes can cause disastrous and costly consequences. Even minuscule holes can invite rust, and poorly-fused welds can lead to breaks, eventually causing things like product failure or failure to meet OSHA industrial access regulations or industry-specific requirements.

Properly trained welders, along with a well-documented WPS program, can prevent project mishaps and delays.

Finding a Company

Finding a company that you can trust could be a challenge if you don’t know what to look for. Welding Procedure Specifications are a great way to determine the quality of the work you will receive. Having Welding Procedure Specifications is essential for every welding company because it maintains quality standards across every weld. It isn’t just a nice guide to follow. Under various international standards, a WPS is required to ensure a stable weld.

No matter how experienced your welding company appears to be, you shouldn’t rely on them to simply guess the best way to accomplish a specific weld. They should provide you with a list of specifications that guarantee their welders can execute an excellent weld in any situation. To maintain consistently high standards, you should look for a Welding Procedure Specification for every type of weld you require for your project.

What is a Welding Procedure Specification?

A Welding Procedure Specification, or WPS, is a formal written document describing standard welding procedures.

Like a recipe for welders, these procedures provide clear direction for welders to make quality products up to code and industry standards. They will include any details and information that are required to make the desired weld.

These are proven and tested procedures that include but are not limited to information such as the materials needed, the tools required, the processes to follow, the techniques they employ and finally, confirmation of the desired outcome.

A WPS goes beyond knowing you will get a great weld. Although a WPS will ensure the welded components meet design requirements, it can also help you determine what company you should go with when hiring someone to create your product. Knowing a company’s welders have skills that are in line with a particular WPS can give you peace of mind and ensure your product will pass inspection and do exactly what it should.

Why You Need Welding Procedure Specification

A company that has an established process to ensure their welders follow Welding Procedure Specifications means you know what you will get without having to see the finished product. Because the WPS should record all pertinent welding information, such as plate dimensions, material type, and welder and operator identifications, it is easy to guarantee the quality of the work.

Here at Yarbrough Industries, we hold our welders to the highest standard. We can provide Welding Procedure Specifications for the most common welding types, including MIG, TIG, welding of carbon steels, stud welding, and welding stainless steels for structural purposes. We are also willing to create a custom WPS for your product when the basics aren’t enough.

At Yarbrough Industries, we only employ certified, safety-conscious welders as part of our documented quality control program. Our Quality Control program adheres to industry-specific safety standards, such as material thickness, in each custom metal fabrication. We provide our clients with documentation for every fabrication, including quality inspection and detailed photographs. Our dedicated manager ensures every metal fabrication meets or exceeds safety and quality standards.

If you’re ready to work with a custom metal fabricator that practices what they preach when it comes to welding quality, give us a chance to say, “Yes, we can do that!” by contacting us today.

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