How Laser Cutting Machines Work

Laser cutters operate by focusing a beam of light

, or laser, on a focused site on a piece of material in order to slice through it rather than using a solid object, like a blade, to cut the object. A computer system enabled with vector graphical software is also necessary. Commands are given to the laser cutter through software which deciphers design geometry to numerical CNC machine code. A laser can also take in data from drawings developed with the aid of computer-aided design (CAD) software.

Configurations of Laser Cutting Machines

The configurations of the machine are characterized based on how the laser beam will come in contact with the material that will be cut. There are three main configurations that work on the X and Y axes. The first configuration is referred to as moving material. In this setup, the material to be cut is put beneath the cutter head. The second configuration is the hybrid laser. Both the table and the cutter head move in opposite axes, offering optimal stability of the beam's path. The third configuration is referred to as the flying optic configuration, employed by Maloya, where the cutting head is the piece of the machine that is in motion. The object being cut is static and this type of configuration produces very clean work. Its rate of motion is also the quickest among the three setups. The flying optic system also does not require clamping down the material being cut, aiding in the speed of the workflow. There are also machines utilizing up to six axes.

Workflow with Laser Cutting Technology

Loading and unloading can take up valuable production time but the speed of cutting with a laser can make up for this. Not having to clamp down the materials to be cut in some instances also saves time. Another consideration is if the laser cutter can be left on. Workers may have to turn turn off the power to unload the machine and temporarily stop cutting. Lighting is also important in a manufacturing environment. Light emitting diode (LED) lighting is becoming more popular for saving energy. More green ways of lighting manufacturing environments are possibilities such as controlling lighting with fluorescent lights by having them turn off through motion sensors.

Laser Cutting Equipment and Maintenance

With the costs invested in laser cutting machines, sufficient upkeep can ensure that they keep running in a safe and reliable way. If the machine is not running optimally, bad cuts can be made. Process control such as checking cutting nozzles, lenses and additional optics should be conducted regularly. Conducting frequent inspections on alignment can prevent many future problems. Sources of air can affect focal lenses of the cutting machine. Lens clarity is extremely important. Operators can tell if a focal lens is dirty by visual inspection and checking it with a polarizer. Another option is to replace a lens or clean it with fine tissue and alcohol. Laser optical components are in the category of consumables. Maintenance of chiller units is also important. They should be started before using the laser cutter. A laser cutter will not be as fast if it has not been maintained. Replaceable parts should also be kept in stock for easy replacement. Keep exhaust systems up to par as well.

Training on Laser Cutting Systems

Laser cutter training should include hands-on and classroom training. It should involve basic operation of the laser cutter such as how to start and shut down the machine, operation and programming of the machine, upkeep and maintenance as well as safety. Oftentimes the supplier of a machine will provide training to the purchaser. Other training could include the creation and loading of drawings, scaling, and rotation. File usage and code as well as use of databases and laser tables and metrics need to be learned. CAD and computers need to be comprehended to use a laser cutter. One should understand how to measure thicknesses of materials in relation to whether the machine can handle cutting them. Blueprint reading should also be a skill held by a laser cutter user. Users need to be trained in quality control and geometric tolerance to know the range of precision of a laser cutter. Material Requirements Planning (MRP) involves planning everything needed for a job as well as inventory taking. Software is utilized for these functions. Proper training on these systems is essential as the common problem with them is the data often has errors. Some of these errors can be taken care of through proper teaching. One should be able to use tools for measuring including calipers or a vernier caliper which can offer measurements that are more accurate. Other basic tools someone should be skilled in the use of are a ruler, protractor, compass and basic mathematical tools.

Quality Control

In order to continually improve workflow processes, Corrective Action Requests (CARs) and Corrective Action Notifications (CANs) can be done. This involves reporting a problem that occurred, the cause of the problem, and future problem preventions. There is workflow quality management software that will handle this. For instance, if something happens, a notification in a certain form such as an email will be sent to the designer who will handle it. Problem correction will be the next step. Much knowledge and skill is needed to use a laser cutter. Having the wherewithal to operate the laser cutter correctly in a proper environment will keep a machine working optimally on many projects for a long time to come.

by: Roger Hug.

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