Manufacturing Process
Laser Cutting
激光切割
High-accuracy thermal cutting of sheet metal and tube profiles with a focused laser beam.
Process Steps
- DXF/3D program
- Laser cut
- Edge check
- Parts separated
What is laser cutting?
Direct answer: laser cutting uses a focused beam to melt and eject material along a programmed path. A fibre laser gives a narrow kerf, a small heat-affected zone and no mechanical force on the workpiece, which is why it is the default choice for flat profiles and tube cuts up to a few millimetres thick.
Laser, plasma, waterjet and wire EDM compared
| Fibre laser | Plasma | Waterjet | Wire EDM | |
|---|---|---|---|---|
| Typical tolerance | ±0.05–0.10 mm | ±0.2–0.5 mm | ±0.10–0.25 mm | ±0.003–0.010 mm |
| Edge | Clean, small dross on thicker plate | Rougher, dross on the underside | Smooth, matte | Very fine, near-polished with finishing passes |
| Heat-affected zone | Small | Significant | None | Thin recast layer |
| Materials | Metals; reflective and highly conductive need care | Conductive metals only | Almost anything, including composites | Conductive materials only |
| Practical thickness | Up to about 20 mm, best under 6 mm | Up to 25–50 mm | Very thick | Up to 200–300 mm |
| Speed | Fast | Fast | Slow | Slowest |
| Best for | Sheet profiles, prototypes, tube cuts | Heavy plate, structural steel | Thick or heat-sensitive material | Tooling, hardened steel, micron tolerances |
The short version: plasma is for thick plate and rough edges, laser is for accurate sheet and tube profiles, waterjet is for anything the heat would damage, and wire EDM is for the last hundredth of a millimetre.
Laser tube cutting
Fibre lasers cut tube as easily as sheet, which makes them the practical route for tubular parts: holes and slots on the tube wall, angled or mitred ends, and profile cuts that would otherwise need a fixture and a mill. Balford runs laser tube cutting alongside tube bending, so a tube can be cut, bent and cut again in one production route.
Where laser cutting fits, and where it stops
- Prototypes and low volume: no tooling, and a design change is a new program rather than a new die.
- Flat blanks and brackets: cut and then formed by bending or welding.
- Tube parts: holes, slots and end profiles without a fixture.
- Where it stops: laser cutting cannot form a part, and at volume the cost per piece is far higher than stamping. Above a few thousand pieces a year, a die is usually the cheaper route — the crossover is a straightforward calculation.
Limitations worth knowing
- Taper and kerf. The cut is not perfectly parallel; the kerf is roughly 0.1–0.5 mm depending on material and thickness.
- Heat-affected zone. Small on a fibre laser, but the cut edge is not the same material as the parent plate. Where the edge will be welded or form a seal, that matters.
- Reflective materials. Copper and brass need the right machine and settings.
- Dross and micro-burr. Usually removed by a light deburr before plating.
Frequently asked
Is laser or plasma cutting more accurate?
Laser. A fibre laser holds roughly ±0.05–0.10 mm with a narrow kerf and a small heat-affected zone; plasma is typically ±0.2–0.5 mm and leaves a rougher edge. Plasma wins on thickness and on cost for heavy plate.
Can laser cutting handle stainless steel and aluminium?
Yes. Both cut cleanly on a fibre laser. Aluminium needs more power because it reflects and conducts heat, and stainless is usually cut with nitrogen as the assist gas to keep the edge clean.
How thick can laser cutting go?
Up to about 20 mm on a high-power fibre machine, but the economics favour laser most below 6 mm. Beyond that, plasma or waterjet is usually cheaper per metre of cut.
When should I switch from laser cutting to stamping?
When the annual volume makes a die pay for itself — typically a few thousand pieces a year for a simple flat part. Laser is the answer while the design is still moving; a die is the answer once it is frozen and the volume is real.
Related: laser tube cutting · wire EDM · sheet cutting · tube bending · deep drawing