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Aluminum Laser Cutting Basics

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  1. Aluminum Laser Cutting Basics

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    Manufacturers of beverages use aluminum laser cutting machines, which are a fast and accurate method for high volume orders. Laser technology goes back to the sixties and has greatly improved in recent years. Here are important facts to consider about laser cutting for aluminum materials.

    What Makes Aluminum Unique?

    Aluminum is an abundant metal, occupying about 8 percent of the Earth’s crust by weight. It’s a non-ferrous metal, along with brass, copper, silver and gold. Non-ferrous means metals besides iron or steel, exhibiting the properties of low weight with higher conductivity and a non-metallic quality. The fact that aluminum is lightweight and soft yet strong and durable makes the material easy to cut or shape on a laser cutting machine. The metal can be easily molded for countless imaginative shapes, which is why it’s a common choice for customization. Unlike iron or steel, aluminum is resistant to rust and corrosion.

    One of the reasons why laser cutters work well with aluminum is because they efficiently remove unnecessary materials in the cutting process. Since aluminum is so flexible, there is usually minimal waste. Whatever scraps are left over can be recycled.

    Laser Cutting Choices

    Carbon dioxide or fiber lasers are frequently used to cut thin non-ferrous sheet metal, although fiber lasers, which use solid state technology, are favored for metals that have strong reflectivity. CO2 lasers, which are driven by gas, have been traditionally thought to work better for thicker metal. But modern advancements in solid-state laser technology opens the door to a wider range of applications for fiber lasers.

    Serra Laser utilizes a option when laser cutting aluminum called “M-Gas”. Nitrogen and oxygen are combined together as the laser assist gas. This function provides a almost machined looking edge and burr free bottom side. Please request this when asking for a quote.

    Aluminum can be cut on various types of cutting machines such as laser, plasma, waterjet or mechanical. Plasma cutting, which is powered by a gas, provides an edge for thicker sheets, but CNC machines are flexible enough to handle quality cutting projects. For those considering the mechanical alternatives, costs will likely be higher, although they favor high volume projects as a cost-effective solution.

    The key advantages laser machines offer over traditional punching machines for aluminum laser cutting are speed and quality. The laser method is also cleaner and more free of defects than mechanical options. Waterjet cutting is a hydro-based solution that is useful for 3D material cutting, but has higher operating costs than a laser cutter. Some fabricators choose waterjet for precision projects.

    Conclusion

    Thickness of material is usually a key factor that determines what type of cutting method and machine is used for aluminum laser cutting. Aluminum is a common material in manufacturing and laser cutters of some type are usually the machines chosen to cut this very flexible metal. Contact us at Serra Laser for more information on high quality and fast turnaround cutting projects.

  2. Keys to Successful Thick Plate Cutting

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    Whether cutting sheet metal or thick plate, the result from a laser cutter is precise. When a company has a need for both quantity and quality, the laser cutter is a strong solution for cutting thick metal. Here are key factors to keep in mind to produce high quality results from thick plate cutting.

    How Material Quality Affects Cutting

    Quality of the metal plays a major role in the quality of the cut, even on a laser cutter. The material must be consistent from its surface condition to its internal elements in order to produce quality parts. Regardless of the type of metal being cut it should have a consistent quality throughout the thick plate. The material needs to be smooth and free of rust, scale and debris. Laser cutters can cut metal cleanly with a thickness up to about 1.00 inch. Beyond this amount crucial factors come into play that involve the quality of the material, gas purity and beam quality.

    Why Assisted Gas Quality Matters

    Thick steel cutting involves using assisted gas in the vaporation and removal of molten material after a cut. The purity of the oxygen or nitrogen is crucial to the speed at which metal is vaporized and discarded. Liquid oxygen usually provides high-purity, whereas oxygen from a compressed cylinder often yields low purities. One of the key concerns when using oxygen is to avoid heat buildup on the thick plate. The thickness of the plate determines how much heat is required to produce quality parts. When programming of the part is done, it is sometimes best to stagger the holes or lines. This controls and dissipates the heat throughout the sheet.

    Based on the material and thickness of metal being cut, the laser cutter can automatically choose from a library of multiple cutting specifications. The machine adjusts itself based on the material being cut, but the operator maintains control of the beam configuration. The quality of the beam is affected by the number of optics and modules in the system. Increasing the number of these components lowers the quality of the beam.

    Benefits of Laser Automation

    Laser cutters are often favored in the manufacturing process due to the fact they can be used to automate processes, including cutting thick metal plates. New high-powered lasers are used to cut heavy-gauge plates even with complex geometric shapes. Laser cutters can be automated to cut gears and sprockets in high volume without any special setup. They can be programed to cut holes the depth of material thickness. One of the most valuable benefits of laser machines is that they can be programed to produce thick plate cutting for hours without assistance from an operator.

    If you’re a manufacturer or metal smith looking for a company to successfully employ thick plate cutting for you, contact us today at Serra Laser and Waterjet.

  3. Precision Laser Cutting Basics

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    When you need products to be manufactured with precision, it’s best to use a laser cutter. More traditional methods of cutting and shaping materials usually involve more steps and create more waste. A laser cutter, however, can be programed to cut with precision and can produce multiple products per minute. Here are key basics for understanding why precision laser cutting is considered high quality and commonly used by manufacturers.

    Cutting With Ease

    One of the key reasons why a laser cutting machine is chosen by fabricators is that it makes cutting metal easy, so it’s useful for productive endeavors. A laser cutter relies on a beam of light that cannot be seen by the human eye, but is powerful enough to melt metal. The beam does not make any physical contact with the material and has minimal thermal impact. Laser cutting is as fine as one-fourth the size of a human hair, making it useful when a high level of accuracy is required.

    High Precision Cuts

    The highest precision cuts are made from lasers assisted with a coaxial gas such as oxygen. This technology is commonly used for making medical tubes. An essential key to making high quality medical tubes is producing high resolution cut paths with dimensional accuracy. Medical tools with jagged teeth are often made by laser cutters, due to their ability to cut less than .001 inch.

    The high level of accuracy on the first cut achieves sustainability since it eliminates the need for further processing, which reduces material waste. Furthermore, the precision laser cutting process has multiple purposes in manufacturing. One of the most valuable purposes for this modern technology is to produce an accurate prototype for a new product.

    Fast Turnaround Time

    Another reason why laser cutters are favored in manufacturing is they can be used to generate a high output of units per day. Fabricators that use laser cutters can guarantee high volume production in a short turnaround time and attract large orders from large clients. Traditionally, faster production has often been at the expense of accuracy. Laser cutting is useful for both expedited projects and high precision.

    Weighing Efficiency

    The only other solution that rivals the laser cutter for high precision cutting is electro discharge machining (EDM), which is not as efficient. The laser cutter, which might only take up six square feet, is more flexible and occupies less space than a typical EDM machine, which commonly uses 12 square feet.

    Since the laser cutter generates less waste and is superior in multiple ways to traditional cutting methods, it should be considered for manufacturing high quality products. Contact us at Serra Laser to learn more about precision laser cutting.

  4. Best Methods for Metal Cutting

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    Accurate metal cutting requires both high precision equipment and skillful operators who understand efficiency. The best scenario is to use an experienced technician who is equipped with modern machinery that is designed for both accuracy and speed. Here are some of the ways metal cutting is done to be as efficient as possible.

    Laser Cutters

    The reason why laser cutting is favored by metal fabrication shops is that it has multiple purposes and can cut metal into any shape, providing great flexibility. The technology is based on a beam of light concentrated on an area to create intense heat that can cut through and remove metal. The laser cutter is useful for high volume projects since it’s capable of automating multiple cuts per minute.

    Waterjet Cutters

    A waterjet cutting machine uses a high pressure water stream and garnet (sand) driven by pumps strong enough to cut metal up to 8 inches thick. The narrow injection of water is useful for metals that are sensitive to extreme heat. The aerospace industry sometimes prefers waterjet to laser because no heat effected zones can be achieved.

    CNC Milling Machine

    The CNC milling machine has existed since the early sixties when computer numerical control (CNC) technology began to surface. CNC machines have evolved to become multitasking machines (MTMs) that can handle various tasks based on the programming.

    CNC milling machines include rotating platforms that allow for easy cutting and are commonly used by fabricators to make metal tools. One of the main reasons for using a CNC machine is to cut unique angles or shapes on metal. These machines are further defined by the number of axes they provide. The more axes added, the wider range of tasks the machine can perform. Serra Laser is equipped with a 3 axis Mitsubishi vertical mill. This machine has a 24 station tool changer to speed up the manufacturing process.

    Other Options

    Plasma cutters are driven by a flammable gas that is pushed through a torch to create a flame hot enough to melt and cut through metal. Plasma machines are useful when high precision is a top priority. Edge quality is not as good as laser or waterjet cutting. Thicker metals where edge quality is not a concern can save the customer a lot of money.

    Cutting metal properly comes down to meeting the goals of your specific project, making it a unique concern for each project. Ultimately, modern metal cutting machines are the solution for work that calls for a reliable high output solution. Contact us here at Serra Laser to learn more about the best options for your cutting needs.

  5. Understanding How Laser Beams Work

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    Laser cutting has revolutionized and accelerated manufacturing processes, particularly those that involve cutting metal, plastic and wood. While commercial laser cutting machines are common among industrial manufacturers, they can also be found in schools and independent workshops. Here are some key points to remember when planning projects that involve laser cutting.

    Widely Used Types of Laser Cutting Machines

    • 2-D laser cutting
    • 3-D laser cutting
    • Tube laser cutting
    • c02 laser cutting
    • Fiber laser cutting

    Evolution of Laser Beams

    Cutting, drilling, marking, and engraving can all be achieved with laser cutters, which first appeared in 1960. The term “LASER” began as an acronym for “Light Amplification by Stimulated Emission of Radiation.” The technology was based on shining a beam of concentrated light on material, in which cutting was an early process. Bell Labs further developed the technology in the mid-sixties when laser drilling was introduced. By the seventies, laser machines were embraced by the aerospace industry. In the following decade, laser machines had become a multi-billion dollar industry serving a wide range of manufacturing industries.

    How Lasers Work

    The column of intense light that forms a laser beam exists on a single wavelength. Most laser beams are in the infrared part of the light spectrum, making them invisible to the human eye. Lasers shine through a beam path but can be bounced around by mirrors known as “bend mirrors” prior to exiting through a nozzle and ultimately the laser cutting head. This intense concentration of light produces heat that melts metal, which makes cutting and drilling easy.

    Laser cutting can be compared with using a magnifying glass to amplify sunlight to burn a hole through paper. With CNC laser cutters it’s important for quality purposes to adjust the focal point in relation to the metal plate either above, at, or below the surface of the plate, depending on the application. The focused beam can be as narrow as .004 inch in diameter.

    Three different general configurations exist for how laser beams move over material, which are moving material, flying optics systems and hybrid. Lasers designed for moving material use a stationary cutting head as the material is moved underneath. Hybrid lasers include a table that moves in the longer axis while the cutting head moves along the shorter axis. These motions are represented by X and Y axes. The term “Z-axis” refers to when a cutting head is controlled.

    One of the key benefits to a laser beam is lack of wear and tear during cuts, making it more efficient and durable than traditional cutting machines. Laser machines allow simple precision cuts and produce less contamination in the workplace.

    Conclusion

    One of the main reasons manufacturers use laser cutters is that they perform fast accurate cuts for various shapes, especially for metal. Contact us at Serra Laser & Waterjet to learn more about laser cut beams or to get a quick quote.

  6. Superior Metal Fabrication with Laser Cutters

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    Metal fabrication is a profession that dates back centuries–long before the industrial revolution. At one time it was closely associated with elite circles and warriors with large swords. The Bronze Age over 3,000 years ago marked the beginning of mixing metals together. Since then, metal has been used for the nuts and bolts that hold the industrial world together. Here are some key elements of metal fabrication to focus on when planning your manufacturing projects.

    Definiton and Applications of Metal Fabrication

    Sheet metal is at the core of the metal fabrication industry, which utilizes techniques for joining metals together as well as cutting, bending, and shaping various metals. Common materials used in the industry include plate metal and expanded metals. Here are typical products that result from the metal fabricating process:

    • aerospace and military equipment
    • automotive parts
    • off road components
    • architectural panels
    • medical industry devices
    • industrial machinery and building materials
    • computer / tech industry

    How Laser Cutters Speed Up Projects

    Although traditional cutting methods are still used even by large manufacturers, laser cutters are considered state-of-the-art for precision and quick delivery on metal fabrication jobs. Not only are the cuts cleaner without degrading sheet metal; laser cutters can also handle various metal thicknesses better than traditional cutting tools. The key to cleaner cuts is that laser beams rely on microscopic heat zones and precision tools rather than physical force. That’s why laser cutters are preferred by professionals for drilling holes placed close together.

    Traditional cutting tools such as saws are based on blades that eventually wear out. Laser cutters, however, do not use blades so they inevitably have more longevity. One of the main reasons for this quality is that laser cutting is a non-contact process. Ultimately laser machines are more efficient and produce less waste due to allowing more parts per sheet, making them the more sustainable solution. They also cut production and material costs substantially. From a design perspective these machines are more suited for engraving fine lines into sheet metal, which can be used for various purposes.

    When identical metal parts need to be repeatedly produced, laser cutters once again are the superior choice. Simply by programming the machine you can roll through several feet of sheet metal per minute to produce hundreds of parts. Other modern alternatives for metal fabrication include plasma cutting and waterjet cutting.

    Customization is another strong reason to go with laser cutters, which allow much more flexibility for cutting unique geometric shapes in metal. Thanks to laser cutters, manufacturers can now promise faster turnaround times. Part of this acceleration is due to eliminating secondary refining processes since precision cuts can be made the first time. Laser machines can also be automated, which means more work can be done with less people, amounting to cost savings.

    Call Serra Laser to Learn More

    Metal fabrication is at the core of industrial manufacturing with laser cutters serving as the high end of manufacturing equipment. Contact us at Serra Laser & Waterjet to learn more about how laser cutting machines speed up and improve the manufacturing process.

  7. What to Know About Plasma Cutting

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    Steel and other hard materials can be cut with a variety of modern machines, such as a plasma cutter. The machine costs thousands of dollars and is used by industrial fabrication shops to manufacture products and machine parts. It’s a device that also works for cutting stainless steel, aluminum, and copper. Here are some important facts to know about plasma cutting.

    Inside a Plasma Cutting Machine

    The main concept behind a plasma cutter is that the machine injects hot plasma through a heated electrical channel and nozzle then into the stock material, as it generates an arc. This path creates an electric circuit with the addition of a grounding clamp. Through the process of ionization electrical conductivity is generated, allowing hot plasma to melt steel with a torch. The softening of the material allows for easy cutting as the plasma and gas remove hot molten metal either on thick or thin plates (although laser cutters are becoming more commonly used for thin metal).

    Why Manufacturers Like Plasma Cutters

    Plasma machines first began to appear in the late eighties in the midst of the computer revolution. The reasons CNC plasma cutters are favored among industrial manufacturers include high speed, high precision and low cost. Since they operate on powerful computerized programming these plasma cutters can also be automated.

    To create the arc in some machines you can connect the torch with the material being cut. Other machines use a high voltage and high frequency circuit, but it’s a more dangerous method since it can lead to electrocution. In machines placed near other electronics, the nozzle can be used as a cathode while the electrode acts as the anode. When these devices touch each other they create an arc like lighting a match.

    The heat from a plasma cutter is so hot it can easily cut metal into any type of geometric shape, no matter how unconventional. Another defining factor of plasma machines is that they can be used on demand through programming instructions. The flexibilty of cutting endless shapes on flat sheet metal is a useful quality. Metal sign manufacturers use plasma cutters for making artistic designs.

    Safety Concerns

    One of the most important tips about plasma cutting is to follow safety procedures set by OSHA. That means wearing proper eye protection from the arc and flying particles. Since hot plasma presents the risk of getting burned, technicians should wear gloves and protective clothing. Some plasma cutters include CNC tables as the computer controls the torch and produces sharp cuts. Newer vertical cutting tables for CNC plasma cutters are now considered safer than horizontal tables.

    Conclusion

    Plasma cutting is an efficient solution for cutting steel and other metals. But it must be performed by seasoned professionals who know what they are doing. Contact us at Serra Laser & Waterjet to learn more about plasma cutting, along with tube cutting and other forms of metal fabrication.

  8. Demystifying the CNC Milling Process

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    A computer numerical control (CNC) milling machine is programmed with electronic tools including a dial and keypad to control mechanical devices such as drills, saws and lathes. A CNC machine is commonly used to manufacture industrial parts, such as engines. Computer-aided design (CAD) software is used to manipulate mechanical processes.

    What CNC Milling Machines Manufacture

    • Products made of metal, plastic, glass and wood
    • Customized machine parts
    • Precision cuts, curves and a wide range of shapes

    Key Parts and Machining Process

    The CNC milling process starts with a designing a CAD model. This model must then be converted into a CNC program. The operator then prepares the machine and executes the program. The primary components of a CNC milling machine are:

    • Parallels
    • Drill bits
    • Limit switches
    • A spindle
    • Table
    • Vise to clamp the stock in place

    Parallels are strips of metal with a series of holes and are used to help mount stock in a vise. The vise should be cleaned with a brush since you need a flat surface for mounting a part. The stock is placed in the device and tightened with a handle.

    The machine contains a door that opens and closes so that you can insert the stock. An edge finder tool is used to identify the stock’s location. The operator shuts the door and selects the manual data input (MDI) button from a menu viewed on the digital monitor. This menu allows you to select tool changes. You then type in the appropriate tool number and press the automatic tool change (ATC) button. The red emergency stop button is used when a part gets disconnected from the vise. The green start button resumes where the program left off.

    Codes and Functions

    A CNC milling machine translates programs identified by letters and numbers. G codes program moving parts while M codes turn devices on or off. Programming involves pressing buttons on a keypad starting with the program button. All programs start with the letter “O” and are numbered. These codes write instructions for the machine to perform specific functions using 16 building block tools. These tools control location, speed and other factors.

    Designs can be cut seamlessly in various shapes from straight to circular patterns. At high speed, you can create complex designs in a matter of minutes. Location is determined by an X, Y and Z axis. The X, Y and Z buttons are controls for moving the parts, as X moves the table left and right, Y moves the table forward and backward and Z moves the spindle up and down.

    You then set the edge finder,  which works most efficiently at 1,000 rpm, with the door closed. If you want better visibility with the door open, it must be set at 750 rpm or lower. Modern CNC milling machines can get as fast as 12,000 rpm.

    Here at Serra Laser, we can use CNC milling either to reverse engineer your part, or to draw specifications from scratch. Contact us to learn more about our capabilities.

     

  9. Basics of Laser Tube Cutting

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    Cutting metal and other materials seamlessly can be accomplished with a state-of-the-art laser tube cutting machine. An operator programs the machine to make specific cuts, making this machine ideal for customized cutting jobs. Here are some essential facts about laser tube cutting to keep in mind when deciding on high precision cuts.

    Benefits of Laser Beams

    The basis of laser tube cutting is the laser beam, which is a narrow beam of light able to make small precise cuts. Lasers are measured by wavelength and are useful for communication processes due to the ability to carry large amounts of information. They are also free of electromagnetic interference and do not involve much signal leakage.

    One of the biggest benefits to using a laser tube cutter is that it can make complex cuts faster than any other machine. We have the abililty to countersink and tap holes into tubes of all shapes and sizes. It’s possible for the machine to bypass the machining process completely for certain parts. The quality of laser cutting machines, particularly for cutting thick materials, is starting to rival that of traditional cutters. However, the place where laser cutting really distinguishes itself is in precision for complex designs. Industrial manufacturing applications involving intricate cutting instructions for small diameters have been enormously sped up due to improvements to modern laser cutters.

    Planning Cuts with CAD Software

    Laser tube cutting is a process planned on computer-aided design (CAD) software. Working with one design platform integrated with a laser cutter allows you to be more productive since you don’t have to waste time importing or exporting programming. The speed of the project will be maximized if the programmer stays close to pure design without getting involved with assemblng or disassembling program components within a model. Key information put into the program should include material type, thickness and geometry of the tube.

    It’s important to use user-friendly software when working with 3 dimensional parts and the programmer should not have to flatten a pre-designed part. The programmer should have access to tools that allow for customized miter cut angles with the ability to alter designs without requiring costly engineering adjustments.

    Speeding Up the Cutting Process

    When you need accurate straight and angled cuts on tubes, an effective solution is to use a laser cutting device with 3D 6-Axis laser technology. The FabriGear 300 is useful for cutting specific shapes while eliminating several steps that are common in the manufacturing process. This high-end machine is needed in fabrication shops to accommodate 3D flexibility for cutting customized shapes.

    Due to the advent of constantly improving laser tube cutting machines, it’s difficult for manufacturers to keep up with learning the fuctionality of these machines. While the software is relatively easy to use, it continues to grow in sophistication and those who keep up with developments gain a competitive edge.

    Conclusion

    Selecting the right laser cutting device with 3D 6-Axis laser technology is key to accelerating the laser tube cutting. Working with experienced technicians who understand the latest laser tube cutting developments also helps ensure high quality cuts. Contact us at Serra Laser to learn more about customized laser tube cutting.

     

  10. Advantages of Waterjet Cutting

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    Based on the concept of a high-pressure water system designed for cutting a wide range of materials, a waterjet is a flexible tool for fabricators. The machine is useful for cutting hard materials like steel or soft materials such as foam. Here are other key advantages to using a waterjet cutting machine.

    Evolution of Waterjet Cutting

    A waterjet consists of a high-pressure water pump that manipulates an articulated cutting head, controlled by a computer program. A nozzle moves with the material as it is cut and a stream of water bends with the direction of the cut. Newer simplified pumps with a crankshaft are considered much more efficient than more traditional hydraulic intensifier pumps.

    Hydraulic machines with steam engines began to appear in the early nineteenth century. The idea of using water for cutting has been around since the Great Depression era. Early devices relied on low-pressure water, then high-pressure water systems became common in the post-war period. By the 1970’s ultra-high pressure water pumps yielded highly reliable waterjet cutters. The result has been faster and more precise cutting.

    The high velocity of water pressure makes it possible for the tool to slice into metal and other hard surfaces. Abrasives were added to water in the 1930s to help speed up the process, which ushered in the waterjet era. When abrasives are not used the process is considered to be “pure waterjet.”

    The waterjet is now used to make sophisticated tools for various industries including aerospace and automotive. It can also be used to carve designs on materials as solid as titanium. By the 1990s waterjets became common among fabrication shops, due to their high output ability. Flow International, which licenses OMAX software, has become the largest manufacturer of waterjet machines. The company has helped simplify the manufacturing process with its user-friendly cutting machines.

    Quick and Accurate Cutting

    Waterjet cutting is favored by fabricators because of their versatility and ability to cut various materials quickly. Since the technology encompasses reliable pumps and nozzles, it can be used to cut almost any material quickly. Waterjets are considered the fastest cutting devices in the world and help speed up the manufacturing process.

    One of the most important reasons to choose a waterjet cutter is that it cuts material without affecting its structure, since it doesn’t produce a “heat affected zone.” The fact that just about any type of material including metal is unaffected by heat gives the machine an all-purpose utility. The device is used by meatcutters, miners and aircraft manufacturers. The waterjet cutting process contributes to efficiency by limiting waste. Curves can be cut so precisely that less scrap material will be left behind.

    Conclusion

    Not only can a waterjet cut through leather or rubber, it can cut through stone or granite. It’s an effective tool for cutting through any surface, making it useful for designing machine parts. Contact us at Serra Laser for more information about waterjets and the most efficient methods for laser cutting.