Why laser cutting should be the ‘go-to’ metalcutting method

Choosing a metalcutting method that is quick, precise and cost-effective can be a difficult task, particularly when there are so many to choose from. Charles Corner, managing director of full service sheet metalwork manufacturer, Malton Laser, discusses the benefits of laser cutting over other processes and why it is fast becoming the ‘go-to’ metalcutting method.

When it comes to metalcutting techniques, there’s a plethora of options to choose from. Whether it’s waterjet and plasma cutting or laser cutting and punching, there’s certainly no shortage of options available on the market. With so much choice, it can be difficult to understand what is the right method for your business.

Our engineers at Malton Laser have extensive experience when it comes to cutting various materials, and have worked with a host of different methods in the past, including laser cutting, waterjet cutting, plasma cutting and punching.

Taking this experience and knowledge into account, we believe that laser cutting is the most efficient, cost-effective metalcutting solution available. Our belief in this technology is so strong that we recently invested in a new Bystronic ByStar 3015 6kW machine in order to refine our in-house laser cutting processes and offer our clients an elevated metalcutting service.

Pros and cons

We’ve experienced far more tangible results when implementing laser cutting compared to other, more traditional methods, such as punching, plasma or waterjet cutting. These processes, however, do have their advantages.

The waterjet method for example, is ideal for cutting thick metals and non-metals. It is also considered a ‘green’ technology as it produces no hazardous waste. Waterjets eliminate airborne dust particles, smoke, fumes and contaminants from cutting materials such as asbestos and fiberglass, again removing waste material disposal costs, reducing health and safety risks for the operator while decreasing final costs for customers.

Nevertheless, there are a number of downsides to implementing the waterjet cutting process that cannot be avoided. While accuracy of the process is high, it is also significantly slower than other processes, resulting in lengthy lead-times.

Costs can increase further when thicker, harder metal is cut using waterjet technology as the abrasive materials needed to complete this process tend to come with a hefty price tag. Initial set-up of waterjet technology requires a lot more investment when compared to other processes, such as plasma cutting, which in turn has a knock-on effect to the price the customer pays.

If speed is what you’re looking for, then plasma cutting is an attractive option. It’s a much faster process than waterjet cutting, increasing production and resulting in faster turnaround times for clients. Clean, relatively precise cuts can also be achieved quickly with this method.

The versatility of high definition plasma cutting is a big draw for businesses requiring thicker cutting processes – materials up to 80mm thick can be cut with ease.

Despite these advantages, plasma cutting does have its drawbacks. The electrodes and nozzle on the equipment’s cutter require ongoing frequent replacement, meaning it can be an expensive process. Plasma can also suffer with bevelling of cut edges, which can adversely affect product quality.

Likewise, metal punching can also offer a quick turnaround with a higher number of jobs being completed at one time thanks to a punching machine’s ability to hold hundreds of tools at once. A punching machine can for instance produce threads or forms into the component. This reduces the amount of time it takes to complete projects, as well as making the process faster and initially more cost-effective.

A major drawback of metal punching however, is that additional metal surface finishing methods are required once the punched component has been made, as the process results in burrs being left on the metal, which need to be removed and can elevate costs.

Winning technology

Having worked with all of these methods over the last 20 years, we believe that laser cutting is by far the best technique when it comes to metalcutting. Laser cutting is not only faster, more accurate and neater – it is so precise that it doesn’t create burrs or surface metal damage, eradicating the need to invest more money in additional metal finishing processes. Offering unrivalled levels of uniformity, as well as efficiency in production, means that customers can be confident in both the regularity and quality of their finished product.

We invested in our new laser cutting machine due to the high speed in which it can carry out cutting processes. The machine is considerably faster than standard CO₂ laser cutting systems, and has resulted in a 100% increase in production since installation.

The accuracy and precision of lasers enable smaller, more intricate components to be cut both quickly and efficiently, without compromising on the quality of the finished product.

Laser cutting machines come with a protective glass layer that protects the lens when cutting. This layer is extremely strong and resilient, meaning hundreds of hours of cutting can be carried out without having to replace machine components, again allowing manufacturers to pass these savings on machine maintenance onto customers.

This reliability is another attractive benefit for customers, as they can trust the machine won’t frequently break down or require recurrent component part replacement, which can considerably extend lead-times and hold-up other projects.

The latest fibre lasers, with massively increased cutting speeds, are capitalising on the advantages laser cutting has over its competing processes. When a company chooses to laser cut its product, it is very rare for it to move these products to any other metal cutting method.

With so many methods to choose from, it can be difficult for businesses to decide which one is right for their products and business. While cost will always be a factor, it is worth considering the end product as the driving factor, particularly if precision and uniformity is required for your components.

Malton Laser specialises in providing a full sheet metalwork service, from laser cutting and pressing to fabricating, powder coating and assembly. Its full service offering has led to Malton Laser servicing clients in a number of sectors across the UK, including food and drink, automotive and transport, architectural and construction, retail, energy and engineering.

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