The technology of laser cutting has fundamentally changed the world of metalworking and metal structure manufacturing. With this non-contact, precise cutting process, production has become faster, more accurate and more economical. Companies that have laser cutting machines enjoy a significant competitive advantage, as they are able to solve complex tasks in-house. The article comprehensively presents the operating principle, areas of application, advantages, cuttable materials, machine types and their automation possibilities, as well as looks at future development directions.
The concept of laser cutting
Laser cutting is a precision cutting technology that uses a concentrated laser beam to separate materials without machining them through physical contact.
The principle of operation of laser cutting
Laser cutting A highly precise and efficient process that uses a high-energy, focused laser beam to cut a variety of materials, primarily metals, plastics, wood, and ceramics. The laser beam emits concentrated heat energy that quickly heats, melts, vaporizes or oxidizes the surface of the material, thus ensuring material removal along the cutting line.
Generation and focusing of the laser beam
The beam used for laser cutting is generated in an optical resonator, where the energy is emitted by a medium (e.g. CO₂ gas or semiconductor) that is excited in various ways – electric current, gas discharge or diode lasers. The resulting laser beam is focused with the help of mirrors and lenses into an extremely narrow, intense beam of light with a diameter of up to 0.1 mm.
The focused beam reaches the surface of the material and suddenly raises its temperature due to the high energy density. Cutting often involves the use of auxiliary gases (such as oxygen, nitrogen or compressed air) to improve the quality of the cut, help remove molten material and prevent oxidation.
Laser types: CO₂ lasers and fiber lasers
CO₂ lasers
CO₂ lasers represent a traditional technology of laser cutting. These lasers use a carbon dioxide gas mixture as the laser medium and typically emit infrared radiation with a wavelength of 10.6 micrometers. Their advantage is a smooth cutting surface, especially for thicker carbon steels. However, their disadvantage is that the system requires more complex optics and regular maintenance, as well as less efficient in cutting reflective surfaces such as copper or aluminum.
Fiber lasers
Fiber lasers represent state-of-the-art technology and are becoming increasingly popular in industrial applications. The laser beam passes through an active fiber optic medium and has a wavelength of typically 1.06 micrometers. This shorter wavelength provides better focusability, resulting in a higher energy density – allowing you to cut faster and more precisely. Fiber lasers are minimal maintenance, have a longer lifespan and lower energy consumption than CO₂ lasers. In addition, they cope much more effectively with reflective materials such as copper, aluminum or brass.
The main advantages of laser cutting compared to other cutting processes
- Excellent accuracy, minimal post-processing.
- Low thermal zone, thus low deformation.
- Flexible use of materials: almost all metals can be cut, but it can also be applied to non-metallic materials.
- High speed, high productivity.
- Automatability, CNC control option.
Areas of application in industry
Due to its versatility and precision, laser cutting can be used in a wide range of industries in various industries. The speed, repeatability and excellent cutting quality of the process allow it to be used economically in both individual and large-scale production environments.
Key Industry Applications
Heavy Industry & Mechanical Engineering
In heavy industry and general mechanical engineering, laser cutting is used to cut thick steel sheets, structural elements, support beams, and other massive metal parts. The advantage of this process is that it requires minimal post-processing, thus reducing production time and costs.
Automotive industry
Precision and speed are extremely important in the automotive industry. Laser cutting allows you to precisely cut car body parts, interior metal parts, chassis components. It is also ideal for prototyping, where it is common to modify the form or produce new parts quickly.
Electronics industry
In the electronics sector, laser cutting is mainly used to make thin metal foils, shielding plates, microstructures, and precision holes and cutouts. Here, a high degree of precision and minimal heat exposure are the most important advantages.
Building Services & HVAC Systems
In the field of building engineering, laser cutting can be used to efficiently produce ventilation ducts, tiles, pipes, supporting structures and other components. With fast cutting times and processes that can be automated, the technology has also become ideal for the HVAC industry.
Sheet metal processing and metal structure manufacturing
One of the most common applications of laser cutting is sheet metal processing. Whether cutting flat sheets, tubes or hollow sections, the laser process ensures clean cutting edges and fast production. It is especially advantageous for parts with complex contours and many cutouts.
Custom production, small series and prototyping
Laser cutting is a flexible technology, so it is ideal for small-scale production, where traditional tooling would not be economical. Thanks to CAD-based control, cutting programs can be quickly modified, allowing for changes in form or the production of new prototypes within a few hours.
Special areas of use
- Decoration industry – cutting out decorative elements, metal decorations, inscriptions, logos.
- Medical technology – precision cutting for the production of surgical instruments, implants and precision mechanical parts.
- Jewelry industry – cutting extremely fine patterns and unique shapes from precious metals.
- Furniture production – design elements, laser-cut inserts, branded panels.
Cutting materials with laser
One of the biggest advantages of laser cutting is that it can process many different types of materials, from metals to non-metallic materials. Choosing the right combination of laser type (CO₂ or fiber) and auxiliary gas (e.g. oxygen, nitrogen, air) is key to cutting quality, speed and cost-effectiveness.
Metals
Carbon steel (mild steel)
It is one of the most commonly cut industrial raw materials. Oxygen auxiliary gas can be used to create a high-quality cutting edge with a strong oxide layer. It is also effective at different thicknesses, it can be cut up to several centimeters thick with high-power lasers.
Stainless steel
Typically, nitrogen auxiliary gas is used when cutting stainless steel, which helps to maintain a clean, oxide-free cutting surface. This is especially important for food, pharmaceutical, and decoration applications.
Aluminium
This light metal is an excellent conductor of heat, so cutting it is a particular challenge, especially in larger thicknesses. However, fiber lasers can be cut efficiently and cleanly, mainly using nitrogen or air auxiliary gas. With the right parameterization, the reflection of the material can be minimized, which can be a problem with CO₂ lasers.
Copper and brass
Copper and brass strongly reflect the laser beam, so only fiber lasers are suitable for cutting these materials. Advanced sensors in modern laser systems help protect the equipment from possible reflected radiation. In the case of these metals, nitrogen also helps oxide-free cutting.
Other materials
Plastics
Certain types of plastics – such as acrylic (PMMA), polycarbonate (PC), or polyethylene (PE) – can be cut well with CO₂ lasers. However, it is important to pay attention to the fact that some plastics (e.g. PVC) can emit hazardous gases when exposed to heat, so cutting them requires a special extraction system or alternative technology.
Wood and wood-based materials
Laser cutting of plywood, MDF, solid wood and veneered boards is also common. The CO₂ laser can provide fine, carbon-free cutting edges, especially in precision work such as furniture decoration or mock-ups.
Textiles, leather, paper
The precision of laser cutting is also excellent for processing thin, soft materials. It is often used in the clothing industry, advertising decoration or in works of art, for example, to cut felt, linen, leather and various synthetic materials into shape.
Special materials
- Foam materials – for packaging purposes, they are often cut with a laser because they do not deform and a clean edge can be formed.
- Ceramics, glass – only with special laser systems, they are more suitable for engraving or marking, as they are prone to cracking due to their brittle nature.
Laser Cutting Machine Types, Performances and Automation
2D Laser Cutting Machines
The most common type of machine used for machining flat sheets. The metal plates are placed on a horizontal table, and the laser head moves along two axes (X-Y). These machines are ideal for fast and precise cutting of various metals (steel, aluminum, stainless steel, etc.), even in medium or large series.
Tube laser
Machines specially designed for cutting round, rectangular or individually profiled pipes and hollow sections. The rotating chuck and automatic material handling system allow you to make complex cuts, holes and curved shapes, for example in the production of frame structures or tubular furniture.
3D Laser Cutting Cells
Equipment that can move along multiple axes, allowing precise cutting of spatial shapes, pressed or welded parts. The 3D laser cutting is ideal for the automotive industry, where, for example, it is necessary to subsequently cut out body parts or intricately shaped metal coverings.
Power – what does watts mean?
The performance of laser cutting machines decisively determines the thickness and type of material that can be cut economically and with the right quality. The power of the machines available on the market typically ranges from 1 kW to up to 30 kW.
- 1-3 kW: Low-power systems ideal for cutting thinner sheets (1-6 mm).
- 4 to 10 kW: versatile use for fast and clean cutting of medium-thick materials.
- Above 10 kW: suitable for heavy-duty industrial applications, fast and stable cutting of thick sheets (>20 mm) as part of often automated production lines.
Important technical note: Higher performance not only results in faster cutting, but also allows for efficient processing of thicker or more difficult to cut materials.
Automation and industrial integration
Modern laser cutting systems They are increasingly integrated into automated production processes. The following elements contribute to increasing efficiency:
- Automatic plate feeders: enable continuous production without human intervention.
- Robotic arm systems: especially useful for 3D cutting cells, for moving and positioning complex parts.
- Smart software and control: They optimize the cutting path, reduce material loss and cycle time. Most systems already work with CAD/CAM integration.
- Remote monitoring and maintenance: IoT-based solutions can be used to monitor machine operation in real time and predict maintenance needs.
Typical errors in laser cutting and optimization options
Typical defects include burr cuts, incomplete cuts, warping, or discoloration of the cutting surface. Most of these are due to incorrect settings, contaminated optics, or maintenance deficiencies.
Professional tip from practice: With the right settings, clear optics and a good auxiliary throttle, these errors can be significantly reduced.
Advances in technology and current trends
In parallel with the technological development of laser cutting, machine types and configurations have also undergone significant development. Manufacturers offer a wide range of laser cutting equipment tailored to different industrial needs, from machining flat sheets to cutting complex spatial shapes. Performance, freedom of movement and a level of automation all contribute to the efficiency and flexibility of production. Laser cutting is not only a mature production technology, but also a constantly evolving, innovative field, which responds to the growing expectations of the industry with new solutions year after year. Increased performance, improved energy efficiency and the advance of automation all contribute to the fact that laser cutting is now one of the pillars of future production technology.
A new generation of fiber lasers
Compared to previous CO₂-based systems, fiber lasers are not only more compact and maintenance-free, but also significantly more efficient. Manufacturers are developing fiber lasers with increasing power (up to 30 kW), which not only cut faster, but also work more stably on thicker materials. The shorter wavelength results in better focusability, reducing material loss and distortion due to thermal exposure.
Direct diode lasers
One of the latest technological trends is the appearance of direct diode lasers (DDL). These devices generate the laser beam directly from semiconductor diodes, so they work with significantly less energy loss. DDL systems are particularly efficient for cutting thin sheets and non-ferrous metals, and their fast response times make them suitable for precise automated environments.
Automated production cells
Laser cutting systems are increasingly becoming part of the so-called smart production cells, where the entire workflow – from the loading of the raw material to the unloading of the finished product – is carried out in an automated manner. Robotic arms, material handling systems and a vision system ensure that the machines can operate 24/7 without human intervention. This is especially important to maintain competitive, cost-effective production.
Digital Inclusion and Industry 4.0
- Laser cutting is fully aligned with the Industry 4.0 approach. Modern machines are equipped with:
- With smart control units that automatically detect material, optimize cutting parameters and communicate with other machines.
- With predictive maintenance algorithms that predict upcoming failures based on sensor data, preventing downtime.
- With real-time monitoring systems that can be monitored and modified remotely via the Internet.
Sustainability and energy efficiency
The latest laser cutting machines are not only more powerful, but also use less and less energy. Fiber and diode lasers operate with significantly better electrical efficiency than previous systems, and they generate less heat, so there is less need for cooling. This is important not only in terms of reducing costs, but also in order to minimize the environmental impact.
Environmental and economic aspects
Although the investment costs of laser cutting systems may seem high at first, they can be operated economically and efficiently in the long run. The introduction of the technology not only increases the speed of production, but can also result in significant cost savings throughout the entire production cycle.
Economically advantageous choice
- Less scrap: The high precision of laser cutting minimizes the number of defective or spoiled parts, reducing material loss.
- Reduced rework requirements: Due to clean and burr-free cutting edges, in many cases no further processing is required (e.g. grinding, grinding).
- Faster production: Modern high-power lasers enable high-speed cutting, reducing production time.
- Labor savings: Fewer operators are required through automated systems and intelligent control, which reduces labor costs.
- Flexible production: Quickly change cutting programs without changing tools, which is an advantage for small series or diversified production.
Eco-friendly technology
Laser cutting is a modern and sustainable solution not only from an economic point of view, but also from an environmental point of view:
- No cutting fluids required: Unlike traditional cutting processes, laser cutting is a “dry” technology, thus avoiding the handling and disposal of hazardous substances.
- Low noise: The process is extremely quiet compared to other metalworking technologies, which creates a more favorable working environment.
- Minimal waste: Precise cutting and optimised material utilisation result in less scrap and falling material.
- Advanced smoke extraction and filtration: The resulting gases and microparticles are collected by closed exhaust systems, so the air quality remains controlled in the workshop.
Concluding thoughts
Laser cutting is not only a precision machining technology, but one of the most dynamically developing areas of today’s industry. With its wide range of applications, outstanding cutting quality, automation and energy efficiency, it plays a decisive role in modern production – from prototyping to large-scale production. Whether metal, plastic, wood or other special materials, laser cutting offers a reliable, fast and economical solution in every case. With the continuous development of technology, the advance of fiber and diode lasers, and the integration of Industry 4.0, laser cutting will remain one of the key elements of the manufacturing of the future – providing a sustainable and competitive alternative for various industries in the long term.
If you need a partner who, in addition to laser cutting, can also work in the manufacture of metal structures, You are also experienced in sheet metal processing, then feel free to contact us. We prepare the work entrusted to us quickly, efficiently and in excellent quality for our clients.
