Laser Cutting
- Precise, High Quality Cut Edges
- Production-Grade Repeatability
- Eliminates Need for Additional Finishing
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Fathom’s Laser Cutting Service
When Precisions Matters
Fine Details and Tighter Tolerances with Fast Production Timelines
If you’re looking for an affordable production technology that’s a cut above other options, then you should choose Fathom’s custom laser cutting service. It’s ideal for creating complex parts with fine details that are impossible to achieve using a punch press – without the cost of tooling. It can also hold tighter tolerances than water jet cutting. Laser cutting is perfect for high-quality prototyping and low- to mid-volume production. Laser cutting is perfect for high-quality prototyping and low- to mid-volume production.
We can use stand-alone laser cutters to produce prototype parts quickly. When paired with automated loading and unloading systems like those we use at our Fathom Denver location, laser cutters are also a perfect fit for medium- to high-production applications.
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How Does Laser Cutting Work?
Laser cutting utilizes a CNC-controlled, high-powered laser beam to cut, engrave or etch material. Because the kerf width is barely larger than the laser beam, it can be used to cut very fine geometries and intricate shapes.
Our fiber laser cutters have a kerf width of .008 inches. That makes them ideal for cutting complex details. The cut is so clean that little or no post-processing is usually required. Fathom’s custom laser cutting service can cut a wide range of materials.
Our lasers can cut .010-.50″ thick materials, +/- .005” with the possibility of tighter tolerances based on project specs – ideal for aluminum, cold-rolled steel, and stainless steel.
There are two main types of industrial laser cutting technology:
- CO2 lasers use energized carbon dioxide gas to generate an intense beam of light to cut material.
- Fiber optic lasers, a newer technology, use light from laser diodes transmitted through optical fibers to generate a high-energy light beam. It’s focused with lenses to create the desired cuts.
In addition to cutting, a laser cutter can etch sheet metal to add features such as part numbers or serial numbers.
What Materials Can be Processed Using Industrial Laser Cutting?
Laser cutting can be used to cut a variety of sheet metal, including aluminum, carbon steel, stainless steel and copper. Some materials have special properties, such as conductivity and corrosion resistance.
Advantages of Industrial Laser Cutting
Affordability // High speed and high quality make industrial laser cutting very cost-competitive and a real value for our customers. It’s an ideal process for prototype to low-volume production quantities of laser cut parts.
Automation // Laser cutters at our Denver facility are equipped with automatic loading and unloading systems, enabling us to process large orders on a lights-out basis. That helps us keep our costs competitive and helps us deliver your finished parts faster.
Precision Details // Laser cutting can produce small, precise holes and fine details in sheet metal.
Tight Tolerances // CNC controls maintain critical tolerances while accommodating fine features and larger blank sizes.
Quick Turn-Around // Laser cutting jobs can be set up and running quickly – perfect for fast turnarounds on small batches of parts. Because laser cutting doesn’t apply any physical forces to the sheet metal, it doesn’t need to be held in place with jigs or work-holding fixtures. That speeds up the setup and production times.
Little or No Finishing Required // Industrial laser cutting produces high-quality edge finishes that require little or no post-processing. Some cleanup of burn marks may be required.
Maximize Material Use // Multiple parts can be cut from the same sheet. That helps to minimize waste.
Disdvantages of Industrial Laser Cutting
Heat-Affected Zones // Because laser cutting generates heat, it can alter the chemical and structural characteristics of the metal near the cutting edge – called “heat-affected zones” (HAZ). Effects may include oxidation, brittleness and corrosion. However, laser cutting generates smaller heat-affected zones than other thermal cutting techniques.
Material Limitations // Laser cutting can’t cut through thicker sheet metal. Water jet cutting works better for thick materials.
Laser Cutting vs. Water Jet Cutting
How does laser cutting compare to water jet cutting? Overall, water jet cutting is prized for its ability to cut a wide variety of materials and thicknesses. It’s extremely versatile. But the sweet spot for laser cutting is producing large volumes of thin metal parts.
These two technologies complement each other. The best solution depends on the material you require, its thickness and the number of parts you need. Ask your supplier which custom sheet metal cutting technology is best for your project. As part of its metal cutting services, Fathom offers both laser cutting and water jet cutting.
Here are the pros and cons of each technology:
Laser Cutting
Pro:
- Laser cutting is significantly faster than water jet cutting.
- The kerf size of the laser is thinner than the water jet’s high-pressure stream.
- Laser cutting can engrave metal by turning down the energy level of the laser’s cutting beam. Water jet cutting can only cut metal.
- Laser cutting produces less waste than water jet cutting. Its by-products are water and metal cuttings, which must be safely disposed of.
Con:
- Laser cutting isn’t suitable for processing thick materials because heat build-up results in melted material along the cutting edge. Water jet cutting can cut through thicker materials than laser cutting.
Water Jet Cutting
Pro:
- Because of its slower cutting speed, water jet cutting is best suited to cutting small numbers of parts. Examples include prototype or customized parts.
- Water jet cutting is a cold process, which means it doesn’t generate heat-affected zones. Laser cutting does create some HAZ effects along the cutting path.
- Water jet cutting produces smooth cut edges that don’t require post-processing. Laser cutting can potentially create burn marks in the metal.
Con:
- Cuts produced by a water jet have a lower tolerance than those made with laser cutting.
- When cutting thicker materials, the water jet stream tends to dissipate near the bottom of the cut. This can cause a slight taper in it.
- Because the force of the high-speed water jet places stress on the material, it may deform thin metal or cause problems cutting small parts.
- The particulate waste from water jet cutting may require special disposal.
Industrial Laser Cutting Specifications
Fiber Optic Laser
- Blinding max cutting speed of >1,800 inches per minute
- 0.008 Kerf
- Thickness capacity
- Aluminum: 0.020″ – 0.500″
- Stainless Steel 0.024″ – 0.500″
- CRS 0.024″ – 0.750″
- Copper 0.020″ – 0.125″
Fiber Optic and CO2 Lasers
- Feature size tolerance +/- 0.002″
- Linear and position tolerance +/- 0.005″
- 5′ x 10′ sheet processing size
How Does Industrial Laser Cutting Compare to Other Cutting Methods?
| Material Thickness | Tolerance | Kerf | Part Volume | Set Up Cost | Lead Time ** | Notes | |
|---|---|---|---|---|---|---|---|
| FIBER LASER | AL: 0.250″ SS: 0.375″ CRS: 0.500″ COP: 0.250″ Brass: 0.125″ | 0.002″ – 0.005″ | .008″ | 1 to High-Volume | Low | 6-8 days | Metals – Fast |
| OMAX WATERJET | Up to 6″ | 0.005″- 0.015″ | .020″/.040″ | 1 to 5000 | Low | 6-8 days | Metal, glass, plastic, stone, rubber, kevlar, carbon fiber, ceramics, etc. Taper up to 59 ° |
| MICROCUT™ | .0005″ – 0.5″ | 0.0005″ -0.005″ | 0.009″, 0.011″, 0.0196″ | 1 to 5000 | Low | 6-8 days | Metal, glass, plastic, stone, rubber, kevlar, laminates, carbon fiber, ceramics, etc. |
| WIRE EDM | 0.001″ – 6″ | 0.0005″ | 0.005″ | 1-200 Is Best | Low | 6-8 days | Conductive Metals, Carbon |
| * CHEMICAL ETCHING | 0.005″ – 0.060″ | Is +/- 10% of material thickness, .002″ min. | Equal to metal thickness | 1- Infinity | $350 Min. | 6-8 days | Metal Only. No Burrs. Beveled Edges. Half Etch and Holes. |
Why Choose Fathom’s Laser Cutting Service?
Accelerate Your Project with Laser Cutting by Fathom
From one part to thousands, we can help you cost-effectively accelerate your sheet metal projects using laser cutting. Fathom’s engineering and production teams have decades of experience with this technology and can advise you on the best process, material and design tweaks to improve the manufacturability of your parts. We can also answer any questions you may have about laser cutting and alternative cutting methods.
Talk to us today about your laser cutting project and how your project can take advantage of its high quality and accuracy.
