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Manufacturing Laser Cut Preformed Parts

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  1. Manufacturing Laser Cut Preformed Parts

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    Today the most effective way for manufacturers to cut preformed machine parts is with a 3D laser cutter. The process involves designing parts in computer-assisted design (CAD) software then programming a laser machine to automatically cut preformed parts quickly on sheet metal, pre-bent tubing or other material. This technology is widely adopted by fabricators to save time and money. Here’s a deeper look at the process of making laser cut preformed parts.

    Characteristics of Preformed Parts

    Preformed parts for machines or other applications can be made from various materials such as aluminum, stainless steel and copper. The type of laser machine affects the quality of the end product and the amount of processing time. These machines are able to cut holes, slots, copes and various angular or tubular shapes with high precision. Usually the thickness of the material is what determines the right type of laser cutter to select.

    For projects designed to be sculptured surfaces, you should use the 2-D or 3-D mode of the laser cutter, depending on the thickness of the parts. Sheet metal with a thickness of .87 inches works effectively for 2-D parts. Laser cut preformed parts help speed up the fabrication process.

    Designing Preformed Parts

    Using CAD software, a preformed parts designer can envision and create plans for parts easily and quickly. 3-D CAD files are transformed into 3-D illustrations of the final products. Once in this mode, a programmer may add modifications to the design. This process encompasses the use of G-code, aka NC-code, a popular numerical control (NC) programming language.

    G-code is used to control the automated process that determines how the motor functions and how fast it moves. The laser and other machine components move according to the instructions in the G-code. The part must fit inside the laser’s work envelope, otherwise the programmer must raise or lower the part. Ultimately, the multiaxis rotary laser trims material based on precise instructions for the cutting path, using X, Y and Z axes on a 3-D grid. Laser machines provide tools for making quick adjustments.

    CAD software, G-code and a laser machine can be used to create endless unique products across multiple industries. They are highly efficient and reliable tools for reducing costs, creating disruptive products and expanding opportunities for customized fabrication.

    Conclusion

    If you are looking for customized solutions for making preformed machine parts, make sure you get the right advice from seasoned experts. Contact us at Serra Laser & Waterjet to learn more about designing and manufacturing laser cut preformed parts for your production projects.

  2. How Laser Marking Improves Fabrication Efficiency

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    Laser marking is used by manufacturers and designers to make a permanent impression on a material such as metal, plastic, film, laminates and others. This process encompasses a wide variety of marking applications. Here are essential points to keep in mind regarding laser engraving to get the most efficient and high quality results.

    Why Laser Machines Are Needed

    Markings on surfaces can be done with traditional hand tools, but the results are usually mixed. The handcrafted way takes much longer, costs more for high volume and lacks the precision of a laser machine. Your product, target market and production schedule will help you determine the appropriate choice: traditional hand tools, or laser equipment.

    Some businesses might choose the traditional method for the sake of customization, but even in that scenario laser machines provide better efficiency. Another reason for choosing traditional marking methods is it may be more practical for small orders with no immediate deadline. But in almost all other situations, laser machines are more effective at delivering products exactly as designed in a shorter time frame.

    Different types of laser machines should be considered based on the materials and time frame involved. Many fabricators use a combination of fiber, CO2, crystal, pulse and other types of laser machines.

    The markings from lasers are permanent and resistant to acids and heat. Laser marking machines essentially deliver faster processing speeds than almost any other technology. They are very effective at marking any type of diverse shapes without loss of quality or additional refining steps. For those practicing sustainability, lasers reduce waste, cost and downtime while meeting regulatory compliance.

    Types of Laser Markings

    Laser technology is very useful for etching and engraving, as it creates markings on materials easily, based on computer programming with design instructions. It allows for easy customization in the sense that the machine can be automated to generate products based on any pre-programmed design.

    The basics of laser engraving involve the laser beam removing surface material, which is often melted and evaporated, leaving an engraved impression. Other types of laser marking include staining, foaming and carbonizing. Staining allows for color variations on surfaces, although staining lighter colors on plastic may lead to darker marking due to the soot residue left behind. Material color can also be altered with annealing marking on metal, in which oxidation occurs beneath the material surface. A common application is engraving serial numbers on tags and machine parts.

    Conclusion

    When it comes to high volume marking, laser marking is the most cost-effective solution available. It also has the quickest turnaround in terms of timing. Contact us at Serra Laser & Waterjet to learn more about the advantages of laser machines and various laser marking strategies.

  3. Important Safety Tips When Considering a Fiber Laser Cutting Machine Purchase

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    Many businesses outsource their fabrication projects to a laser cutting company. This can be a wise move if they don’t have the proper equipment, financial resources or trained staff to do the job themselves. But if you’re ready to purchase a machine to bring your fiber laser cutting projects in house, here are four factors to keep in mind regarding safety.

    Designate or Hire a Laser Safety Officer

    When your business operates a fiber laser cutting machine, certain safety regulations must be in place. Lasers are classified one through four, which determine their level of risk for harm. Class I is safer than Class IV, which can cause serious damage.

    A Laser Safety Officer (LSO) is an employee that is specialized in lasers and laser safety. Their job is to ensure that lasers are used and maintained safely by either performing a necessary task or ensuring it is performed by someone else. Though the assignment of an LSO is not typically required with a Class I or II laser, businesses should consider it, as even lower classified lasers can cause damage. In some cases, an employee may be designated as the LSO and must undergo proper training, whereas other companies may hire a professional LSO.

    Enclosure

    Fiber lasers can be purchased as open or closed machines. Since fiber lasers emit a potentially harmful beam, at certain classification levels they should be enclosed to prevent a safety hazard. If your fiber laser is closed within the machine already, you won’t need to worry about this. If the laser machine is open, you may need to purchase laser curtains to create an enclosure. Anyone’s eye could catch a wayward beam as they walk past. If they aren’t wearing proper eyewear, there could be serious consequences.

    Eye Protection

    Protecting your eyes from the harsh ray of a laser beam and its reflection is crucial. Safety goggles are a smart choice for protecting your eyes, and some lasers even come with them. It’s best to confirm that the goggles are suitable for protection from that specific laser’s rays, and the necessary information should be etched on the goggle’s frame. In addition to protecting your eyes, it is also important to protect your skin, as lasers can burn skin too.

    Ventilation

    Fiber lasers give off gases. These gases and particulates can be harmful to the lungs, depending upon what is being cut. Many of us know to cover our eyes when using a laser, but it is also important to protect the air we’re breathing. There are certain materials that, when cut with a laser, produce noxious gases that can lead to serious health problems. One such example is PVC pipe, which releases chlorine gas when cut. Here is a full list of materials to never laser cut. Though not all materials release noxious gases, it’s important to have proper ventilation no matter your operation size.

    If you’re looking to purchase a fiber laser cutting machine, Serra Laser is your source. We have 30 years of experience selling industrial lasers and can find the right machine to fit your needs. Contact us today.

  4. Important Factors in a Laser Cut Acrylic Project

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    Acrylics are polymer fibers that were first developed by DuPont in the early 1940s. These fibers often make up the materials for sweaters and tracksuits due to the warmth they provide. Since these wool-like fibers have incredible strength, they are used for furniture and travel bags. The laser is an ideal tool for cutting this strong material.

    Laser Cutting Decisions

    When working on a laser cut acrylic project, it’s important to decide if you are creating finished products with a flame polish or if the items will need additional refining. Setting this goal determines the type of cut necessary for a certain edge quality. The variables affecting the way acrylics should be cut are the brand and type, in which the factors affecting laser production quality are power, frequency and speed.

    Acrylics are commonly cut by a process of vaporizing the solid material. As the material transforms from solid to liquid to vapor, the laser is absorbed by the material. Since this vapor is flammable, cutting acrylics should always be overseen by a human and not just left to a machine. A strong vacuum or fan is needed to remove excess vapor and a stream of air is needed to help blow away dangerous fumes in any laser cut acrylic project.

    Factors Affecting Cut Quality

    Plexiglas, manufactured by Evonik, is one of the most well-known acrylic brands. Each brand offers multiple types of acrylics in which colors and thickness may vary. Once the cutting material is determined, you must then decide the type of laser cut and the metrics for power, frequency and speed. The desired cut quality plays a big role in determining speed, as lower speeds deliver higher quality. Material thickness is also a crucial factor. Serra Laser can cut up to 1 inch thick acrylic.

    Other factors that affect the cut are lens and focus controls for beam radius and waist length. The quality of the lens has a direct impact on the shape and quality of the cutting edge. Thicker materials usually require a higher quality lens. The focus feature helps determine the focal point while defocusing leads to a higher quality cut.

    A cutting table is necessary when the goal is high quality flame polishing. It allows you to utilize the acrylic cutting bed that absorbs laser energy. Once the acrylic is cut, it produces several flammable gases, which is why you need a reliable exhaust system that helps move dangerous gases away from the cutting area. This exhaust helps the acrylic material melt and turn into a liquid.

    Prior to cutting, the material should be prepared, which may involve removing film from the acrylic. Gas is also used in laser cut acrylic operations. Sometimes nitrogen is used for making the cutting process cooler, although an internal air assist pump is a much more affordable option. Acrylic material can be damaged at a certain temperature.

    Conclusion

    An easy way to cut acrylics is with a laser, as long as you take the proper safety measures. Contact us at Serra Laser to learn more about laser cut acrylic solutions.

  5. The Revolution of CNC Milling Machines

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    Manufacturers commonly use computer numerical control (CNC) milling machines for cutting, tapping, countersinking and cutting complex features. CNC milling machines help save time and money, allowing fabricators economic ways to transform objects into products. Here are key points to know about CNC machines and why they are widely used across many industries.

    How CNC Machines Have Revolutionized Milling

    Prior to the rise of CNC machines in the sixties, milling – or the cutting and drilling process to make tools – was done with manual tools. These days CNC milling machines with 2 to 5 axes are favored due to accuracy from computer programming. Axes are labeled letters such as X and Y, which associate with horizontal movement, whereas Z is used to reflect vertical movement.

    Jobs can be completed much quicker without sacrificing quality. The machines are used for making parts in various industries such as aerospace and medicine. They are also commonly used for machine components, offroad components and prototypes. A milling machine has the capability of milling a wide variety of precision shapes on wood, plastic and metal that cannot be created manually.

    Although CNC machines are capable of cutting through any type of object, it’s mainly used for cutting metal. There are multiple types of CNC machines that must be considered for any given assignment. Some machines are more appropriate than others for cutting thick metal.

    Why CNC Machines Are Favored for Prototyping

    A common use of CNC machines is to create a prototype of a new product. The machine can be programmed to make complex cuts quickly, making it useful when adjustments need to be made on prototypes. It’s the ideal choice for high volume repeatability. The machine relies on digital instructions from a CAM or CAD file.

    The tools on a CNC machine are capable of doing the jobs of classic workshop machines such as grinders, drills and lathes. These machines come in different types, such as laser cutters, plasma cutters and water-jet cutters. CNC machines with laser cutters are becoming more widely adopted over traditional cutting tools for prototyping because they provide greater efficiency. Key benefits include easy testing, accurate replication and environmental sustainability. Using CNC machines reduces waste and costs of raw materials.

    Conclusion

    Cutting shapes, tapping, countersinking and drilling holes to make machine parts does not have to be a long drawn out process, which is why manufacturers are increasingly using CNC milling machines for prototypes and products. Contact us at Serra Laser for more information about how to meet deadlines on prototypes quickly using CNC technology.

  6. A Deeper Look at Laser Cut Thin Metal Fabrication

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    A primary reason why fabricators use laser machines is because they are effective at cutting various type of sheet metal, as long as it isn’t too thick. For thicker plates, manufacturers use plasma cutters. Thin metals can be cut with various tools, but the key advantage to laser cutters is that they provide precision without using excessive energy, which cuts production costs. Here’s a deeper look at laser cut thin metal fabrication.

    Thin vs. Thick Metal

    The thickness of sheet metal is expressed by gauge, usually in millimeters or inches, which can be found with a tape measure or gauge tool. The higher the gauge, the thinner the sheet, similar to the way a rating system works. A gauge of 10, for example, has a thickness of .135 inches for standard steel, whereas a gauge of 20 has a thickness of .040 inches. Gauges for sheet metal tend to range from 7 to 30.

    But this form of measurement differs between metal types, depending if they are ferrous or non-ferrous. For stainless steel, a gauge of 10 equals .135 inches while a gauge of 20 is .040 inches. The scale system differs for galvanized steel and should not be confused with wire gauges.

    Lasers are useful for cutting thin sheet metal and foils because they make clean cuts without extra labor for refinement. Industrial manufacturers use laser cutting for machine and electronic parts, notably in the automotive and medical industries. Thin sheet metal used for shearing and splicing tends to be below 6 mm in thickness. In general, sheet metal thickness ranges from about 0.15 to 6.3 mm. Thinner metal is called “foil,” whereas metal thicker than this range is called “plate,” which is more appropriately cut by plasma cutters.

    Advantages to Laser Cutting

    Laser cut thin metal is favored by manufacturers over traditional methods partly because it’s the most efficient and modern way to cut such material. It doesn’t require the maintenance of older machines in which cutting blades must be sharpened or replaced periodically. Since the laser has minimal force on the metal due to no contact between the beam and the material, it reduces the chances of damaging the sheet metal.

    A laser is much more precise for detailed patterns than a band saw and allows for more control since it’s automated based on computer programming. The main two ways thin metal is cut are gas-assisted and galvanometer-steered. The former uses table motion while the latter relies on beam steering, which is useful for high speed repeititious projects.

    Conclusion

    Sheet metal gauge determines what type of cutting machine to use, as lasers are very effective at cutting thin sheets of various types of metal. Contact us at Serra Laser to learn more about the advantages of laser cut thin metal.

  7. Making the Most of Precision Wood Cutting

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    Laser cutters can be used to cut or manipulate a wide range of materials, including wood. For high-end precision wood cutting, many fabricators use either a 2-D or 3-D laser cutter. Key reasons why lasers are favored over other cutting tools when it comes to woodwork is the speed, accuracy and versatility they provide. Here are some of the basics to know about wood cutting projects using laser machines.

    Wood Cutting Projects

    The list is long for the various applications of precision wood cutting, which is used in many industries. Here are some common examples for cutting wood projects:

    • cabinets and shelves
    • handles for brooms, silverware, rails
    • frames for paintings, doors and windows
    • hardwood flooring
    • arts and crafts
    • decorative panels

    Computer numerical control (CNC) machines, in which designs can be programmed and then cutting is automated, speed up production, even for curves and diagonal cuts. Many fabricators use CNC routers for certain woodcutting, but it’s not a universal solution for all types of cuts. These routers are not suitable for sharp angles or wide cuts and often require manual labor to complete the project.

    The machines that work best for universal woodcutting, as mentioned earlier, are 2-D and 3-D laser cutters, in which both fall under the CNC umbrella. These laser cutters save time and money compared to traditional methods, while providing a high level of accurate cuts. They are very useful for creating quick high quality prototypes and making last minute adjustments. The concentrated laser in these machines is capable of melting, burning or vaporizing wood.

    While the 2-D laser cutter is appropriate for two-dimensional cuts, the 3-D laser cutter is superior for either two-dimensional or three-dimensional cuts. Both machines are effective for cutting a wood thickness of .005 inches to 1 inch.

    Engraving on Wood

    Reasons for engraving on wood vary from adding aesthetics to numbers or words used for identifiers or sign messages. Laser engraving is suitable for wood and gets a job done much faster than the old chiseling by hand method. The design is planned in AutoCAD software, then the engraving process is automated by a CNC machine. The laser beam shines through a lens, allowing it to cut into the wood based on the programmed design while tiny wood particles are removed from the surface.

    One of the issues to keep in mind for woodworking is that it’s easier to control precision wood cutting by using hardwoods. Softer wood requires lower power and results can be mixed. Another issue is that wood can warp when heated or bend when exposed to moisture, so it must be stored properly prior to production.

    Conclusion

    Modern woodcutting is done most efficiently with CNC machines, which allow for accuracy and quick turnaround times. Contact us at Serra Laser to learn more about the fastest and most economical methods for precision wood cutting.

  8. The Basics of Laser Cut Copper

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    Copper is a vital component in many industrial, technological, and engineering projects. Cutting copper is a challenging task because the metal is more of a reflector than an absorber of infrared laser light. While there are several different types of laser cutters, we most often recommend fiber lasers for cutting copper and other non-ferrous metals. Below we’ll share a little more about why, and how the advanced machinery at Serra Laser can help you get the best results from your copper manufacturing process.

    Why Manufacturers Choose Copper

    The main advantages to using copper for industrial manufacturing are its thermal and electrical conductivity properties, as well as its resistance to corrosion. It can also be converted into wire or shaped in various ways without losing its strength. The laser cut copper strategy is useful for cutting materials used in construction, electronics, and plumbing. Copper is also highly effective for creating alloys with other metals. These alloys hold many of the same properties as copper, and therefore pose the same challenges when determining the best way to cut.

    Selecting the Right Laser Cutter for Copper

    Even though there are a wide variety of options available for cutting copper, some of them work better than others.

    Traditionally, a CO2 laser was used to cut copper due to its ability to cleanly cut thick material. However, the sheet of copper had to be coated with a graphite spray or milk of magnesia in order to prevent reflections, which could damage the laser. For a long time, CO2 lasers were the best way to cut copper and a popular choice in the industry at large. More advanced technology came into play around 2008 with the fiber laser. Fiber laser cutting made cutting copper more efficient and economical, as the beam does not reflect back into the resonator and cause damage.

    Fiber laser cutters are also a strong choice for cutting copper because they can cut a versatile thickness of materials, from thin to thick. Fiber lasers can also cut a high volume of materials, making production faster for manufacturers.

    Making Purchasing Decisions

    Here at Serra Laser, we handle cutting and milling for many different manufacturers, which gives us a chance to see different styles of metal fabrication up close and personal. We have experience with many different kinds of machines, from traditional CO2 laser cutters to waterjet and plasma cutters. Depending on the planned use and application, these alternative cutting methods may be preferable. However, when cutting copper, we usually utilize a fiber laser cutter in order to get the best results for our clients.

    We also sell cutting machines, working closely with buyers to determine the best cutting machine for their needs. When it comes to cutting copper, we usually recommend one of our amazing fiber laser machines, such as the IPG Fiber LaserCube flatbed cutter, which is excellent for small parts, or the Hands Fiber Laser machine, which is ideal for large sheets and thicker materials.

    Conclusion

    Despite copper’s reflective qualities that make it challenging for cutting, it can be cut by various laser cutters. Contact us at Serra Laser & Waterjet for further information about laser cut copper.

  9. The Uses of Tapping and Countersinking

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    While a CNC machine can handle a wide range of cutting, sometimes manual tapping and countersinking are needed to add finishing touches to a machine part. Tapping involves cutting threads on the inside surface of a hole. Countersinking means cutting a conical hole into metal, usually to allow space for a screw or bolt. Sometimes the project calls for customization so that a human must assist the automation. Both tapping and countersinking add subtleties to functions and designs of screws.

    Precision Tapping

    Tapping must be done with precision so that the hole works properly as a fastener. The manual tool that achieves this goal is called a tap, which can also be used for cutting threads on the inner surface of nuts. Tapping can also be done on a tapping or milling machine or a lathe. While a tap or equivalent is used to create the female portion of the fastener, a die is used for making the male part, such as a screw. The die, which comes in various shapes and sizes, can cut a thread on round tubes. The work piece is typically smaller than the diameter of the die.

    The operator, working at a tapping station, must align the tap with the hole properly to avoid angular errors that may result in breaking the tap. The direction the nut will move is established with the cut of the first few threads. Various lubricants may be used during the tapping the process for smoother operation.

    Countersinking and Its Benefits

    One of the main reasons to use countersinking is to prevent corrosion by allowing for a tight seal. It’s useful for long-term installations, such as underground piping, boosting the quality of both workmanship and installation. A countersink expands the diameter, allowing for a screw head to make a more secure connection. It can be applied to sheet metal fabrication for the manufacturing of any fastening device for any existing hole.

    Boring a larger hole allows for the fastener to fit snug in the hole. The covered screw is protected and has a longer life span than an exposed screw. Another advantage to countersinking is that it can prevent sharp edges from extending and causing damage. The wider hole used in the countersinking technique reduces sharpness. Dimpling is similar to countersinking in the sense that conical holes are arranged in rows and columns of sheet metal. This method allows for easy stacking and transportation of sheet metal.

    Conclusion

    Tapping and countersinking are helpful additional processes for customizing machine fasteners to create more stable solutions. Contact Serra Laser for answers to your questions about using the most efficient solutions for metal fabrication.

  10. How to Utilize Titanium Laser Cutting

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    Titanium, like aluminum, is a non-ferrous metal because it lacks iron, so it resists corrosion. The metal maintains strength while bonding with other elements such as oxygen, which is why it’s commonly used as an alloy. Here are key points to keep in mind about titanium laser cutting.

    Strength of Titanium

    Although titanium is as strong as steel, it’s about 40-45 percent lighter.  It also has a melting point higher than 3,000 degrees F, making it useful as a refractory metal, which has a strong resistance to wear and tear. The surface of the metal is so strong that titanium is being considered by scientists as a material for storing nuclear waste. It’s currently used in a wide variety of surgical implants and tools by the medical industry. It’s a favored metal due to its non-toxic qualities and resistance to corrosion.

    Deciding on how to cut material as strong as titanium usually comes down to the thickness of the metal. Thick titanium plates are more efficiently cut by a carbon dioxide laser due to its higher power capacity than other laser cutters. Laser cutters are preferred over mechanical machines because of the ability of laser technology to cut small holes in relation to the thickness of the metal.

    Cutting Titanium with a Laser

    The most efficient way to cut a sheet of titanium metal is with a CO2 laser that uses either nitrogen or oxygen as its assisted gas. One of the issues that technicians must be aware of is that titanium can burn from the laser’s heat. In some cases, modifications must be made to the nozzle and special mixtures of gas must be made to prevent the metal from burning.

    With twice the elasticity of steel, titanium has flexible qualities. Its non-toxic and non-metallic qualities have provided multiple applications for tools in the medical industry. Titanium alloy tools are also used by the military and the aerospace, chemical and sporting good industries. The fact that titanium weighs half as much as steel makes it attractive for machine parts.

    CNC machines are commonly used by fabricators for titanium laser cutting because they provide automated cutting capabilities based on programming. They deliver the fastest and most accurate way to cut thick metal without sacrificing quality. Even though titanium can be cut with manual tools at lower cost, CNC machines are more efficient for high volume runs.

    Conclusion

    Titanium is favored in manufacturing for its strength as an alloy, yet lighter weight and resistance to corrosion. Laser cutters, particularly machines with CO2 lasers, are commonly used for titanium laser cutting. Contact us at Serra Laser to learn more about our fabricating services.