Neat Works

How Laser Cutting Machines Work

Laser cutters work 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 translates design geometry to numerical CNC machine code. A laser can also take input from drawings developed with the aid of computer-aided design (CAD) software.

Laser Cutting Machine Configurations

The configurations of the machine are defined based on the way the laser beam will hit the object to be cut. There are three main configurations that act on two axes, the X and the Y. 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. The table and the cutter head operate in opposing directions, giving the best stability of the beam’s path. The third configuration is the flying optic configuration, employed by Maloya, where the cutting head is the piece of the machine that is moving. The object being cut is static and this type of setup creates neat work. Its rate of motion is also the fastest 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 laser cutting can make up for this. The unnecessary need for material clamping can also save time. Another consideration is if the laser cutter can be left on. Workers may have to turn off the power to take materials out of the machine and interrupt the flow of 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 these types of environments are becoming available such as controlling lighting with fluorescent lights by having them turn off through motion sensors.

Laser Cutting Equipment and Maintenance

With the money spent on laser cutting machines, sufficient upkeep can ensure that they operate optimally and safely. Undesirable cuts can be produced if the machine is not running at its peak performance level. Process control such as checking cutting nozzles, lenses and additional optics should be done on a frequent basis. Simply making regular checks on their alignment can save many headaches later. Air sources can affect focal lenses of the laser cutter. Making sure the lenses are clean is of utmost importance. Operators can tell if a focal lens is dirty by visual inspection and checking it with a polarizer. A lens can then be cleaned with alcohol and fine tissue or replaced. Laser optical components are in the category of consumables. Maintenance of chiller units is also important. They should be started prior to cutting. A laser cutter will not be as fast if it has not been maintained. Replaceable parts should also be kept available if they are needed. 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, how to properly use the cutter and programming of the machine, safety and maintenance. Oftentimes the supplier of a machine will provide training to the purchaser. Other training involves how to create drawings and load them into the laser machine, scaling, and rotation. Other things to be learned are file usage, code, databases, laser tables and metrics. Users of laser cutters should also understand CAD and computers. One should understand how to measure thicknesses of materials in relation to whether the laser cutters can cut them effectively. A user should also be able to read blueprints. Users need to be trained in quality control and geometric tolerance to know the how precise the laser cutter can get. Material Requirements Planning (MRP) involves planning everything needed for a job as well as inventory taking. Software is used for these tasks. Proper training on these systems is essential as the common problem with them is the data often is erroneous. Some of these errors can be eliminated through training.

One should be able to use measuring tools such as calipers or a vernier caliper which can offer more accurate measurements. Other basic tools someone should be able to use are a ruler, protractor, compass and basic mathematical tools.

Quality Control

In order to keep improving workflow processes, Corrective Action Requests (CARs) and Corrective Action Notifications (CANs) can be done. This involves problem reporting, the cause of the problem, and future problem preventions. There is workflow quality management software that will handle this. For example, if something happens, a notification in a certain form such as an email will go out to a person who handles that problem. The action will then be taken to correct the problem.

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.

About the Author

Roger Hug is the Vice President of Sales Engineering of Maloya Laser, leaders in turnkey product manufacturing and contract metal manufacturing servicing aerospace, medical, machinery, scientific and transportation requirements.

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