Trends in laser cutting

Having the greatest. That's what it was often about, at the sheet metal working trade shows in recent years. Then, of course, we are talking about the power of the fiber laser source that manufacturers liked to go all out with. The race still seems to be on, some Chinese brands are already cutting with more than 50 kW of power, but the European brands seem to be content with 30 kW for now. There, other developments in cutting techniques play at least as big a role in order, on the one hand, to keep expanding the playing field of the fiber laser by being able to handle more operations and, on the other hand, to further increase the quality of the cut even in thick material. But of course, machine designers are equally responding to the demand for greater automation and durability.

The CO2 laser has a pretty long history behind it. From its introduction in 1963, it took until 1975 before it was ready for real cutting work in the metal industry. It was the stormy rise of the fiber laser that finally killed it. By now, many manufacturers have consigned this laser source to the trash and only cutting machines with fiber laser sources are built - a still young technology, by the way. When it was introduced at the end of the nillies, it was predicted only a future in thin plate. Today, like a warm knife through butter, it already cuts through 25 mm thick steel as standard. An evolution that, if we compare it to the CO2 laser, has gone several times faster, thanks to advances in optical technology. A bit like the comparison in cutting speeds between the two.

Power races run?

Today, every self-respecting manufacturer has a model that can handle a power of 20 kW. Good for speed and precision in cutting steel up to 45 mm thick. Thus, after the CO2 laser, it already competes with plasma cutting. For whom the bulk of the materials remain below 10 mm, an investment in such a powerhouse will be overkill. After all, its higher price tag then carries you along on the thinner sheet metal as well, and so the cost per piece goes up again. But of course they did prove themselves as a highly complementary second or third laser cutting machine, or as the ideal choice for those who want to work their way through more difficult or thicker materials. Then that higher power is just extremely efficient. But does it need to be much higher? What good is an ultra-powerful laser beam if it also rips the cutting table beneath the pieces to shreds? The whole construction of the machine must be adapted to channel those powers correctly. Another hefty investment for the fabricators, wonder when it will pay off.

Introduction of new cutting techniques

That power would stagnate, however, does not mean that efficiency or quality should remain stagnant. Over the past few months, striking new cutting techniques have emerged, and each machine manufacturer has given them a somewhat different name or dressing. The starting point is clear: playing with the parameters of the laser light to better adapt it to the application. This should close the final gap in terms of cut quality. This happens not only in the laser head, but especially in the generator where the beam is created. Thus, a beam tailored to the application is created. A narrower diameter with high density for thin stainless steel, for example, or a wide beam for thick, heavy material. The intensity of the beam and where exactly it lands (convergence point) and the three-dimensional shape of the beam are also playable. These then require custom fiber optic cables, though. And, of course, smart control. It cannot be the intention that the operator has to determine this entirely by himself.

Bevel cutting head, weapon in competition with plasma cutting

Second novelty introduced here and there: bevel cutting. This ties in with the trend of being able to do more on the same machine. Laser cutting machines must also become Swiss pocket knives, whatever their origin. With a bevel cutting head, they can already give workpieces the perfect weld seam preparation. An unmissable feature for those who want to compete with a plasma cutting machine in the thick plate segment. It is already well established there. But the technology of a laser cutting machine offers the same precision of a straight cut and has less heat influence. So it can handle a higher complexity of pieces.

More stable cutting for autonomous operation

Other introductions deal with those two general economic trends: automation and sustainability. As for automation, reliable cutting is key. Anyone who wants to add an unmanned extra shift to their production schedule at night or on weekends must be able to count on their machines. Pieces that get stuck in the skeleton are therefore out of the question. More reliability can be created by playing with nesting, with the width of the laser beam or with micro-joints (or even nano-joints at one manufacturer). In addition, an automatic nozzle changer with quality control will be an interesting addition. Not only do these make it possible to also cut further by replacing the worn nozzle. It will also help to be able to create the right jet for each application.

Becoming more sustainable

But of course, it remains a matter of making the most of every inch of plate for those who want to fulfill their sustainability ambitions. On top of that, new features are being introduced to bring down the energy consumption of fiber lasers (which, by the way, are already the more sustainable choice over the CO2 laser, up to 60% more energy efficient) and the cooling required. By putting systems on standby, by making cycle times shorter, by smart LED lighting... Another possibility is to make the machines more compact so that they require less material. Anyway, most manufacturers have deployed the roadmap to become energy neutral.