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CNC Laser cutting of metal, modern industrial technology. .

Applications of IoT in Laser Cutting

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While laser cutting has many advantages, it can also be challenging to implement. High initial costs, safety concerns and the need for specialized training can stop manufacturers without the necessary funds and experience from capitalizing on its potential. Internet of Things (IoT) functionality in the laser-cutting process can help businesses overcome those barriers. Smart home devices are some of the most familiar examples, but many industrial-grade, manufacturing-specific IoT solutions exist. This blog will look to highlight the applications of connecting IoT with laser cutters and how it can benefit manufacturers.

Improved Safety

One of the most significant advantages of IoT connectivity in the laser-cutting process is its impact on safety. Lasers can be dangerous, causing safety hazards such as amputations and even death when employees get in their way. This equipment can also emit hazardous fumes, presenting less noticeable but still serious risks. The IoT helps by creating distance between employees and these metal fabrication safety hazards. Workers can operate IoT-enabled laser cutters remotely without losing any precision. Consequently, they can run this equipment continuously without worrying about amputation or fume-related risks. Protecting employees’ well-being is enough to warrant these safety improvements on its own, but they also have tangible business benefits. Fewer injuries mean less unexpected downtime and fewer losses from workers’ compensation payments. Those savings can justify the higher costs of implementing IoT-connected laser-cutting equipment.

Real-Time Operating Data

IoT in laser cutting also lets mining plant and equipment Australia operators capitalize on real-time data. Connected sensors can gather data on operational factors like temperatures, cutting speed, material thickness, beam power and more and transmit it to workers in real-time. This insight enables more effective control. Data standardization is key to maximizing manufacturing efficiency, but businesses must realize that some manufacturing data issues are inevitable. In light of that unpredictability, employees must be able to adjust to these changes, which the IoT’s visibility enables. When laser operators can see changing conditions in real-time, they can adapt to them to maintain productivity and accuracy. An IoT sensor may reveal that a laser is not cutting material as quickly as it should, informing the operator to temporarily dial up the beam’s length, temperature, or pulse rate. Alternatively, warnings about warping or excessive temperatures can tell employees to dial these factors back. By adapting to these changes, workers prevent errors and maximize productivity.

Flexible Automation

IoT connectivity can also enable flexible automation in laser cutting. Automated cutting processes are more efficient but can be challenging to implement effectively because they often mean sacrificing adaptability. The IoT provides a solution by letting automated systems respond to real-time data from upstream processes. IoT-connected automated laser cutters can communicate with other IoT equipment earlier in the manufacturing process. They can then receive data on any unexpected delays, material irregularities or other disruptions and adjust accordingly to compensate for these unusual situations. That way, variability elsewhere in the production line will not disrupt automated laser-cutting processes.

Enhanced Inventory Management

Laser cutting can also benefit from IoT implementation outside of the laser cutter itself. Inventory management IoT solutions are an excellent example. By boosting inventory visibility and efficiency through the IoT and ensuring efficient communication, manufacturers can ensure a smoother laser-cutting workflow. IoT tracking solutions in material inventories can provide real-time updates on things like upcoming parts’ composition, thickness and other factors that impact cutting. With this information in hand, laser cutter operators or automated systems can adjust ahead of time to account for any irregularities or changes. That way, they can ensure they cut the material as quickly, safely, and accurately as possible. Adapting to unique material qualities can significantly impact productivity.

Final Thoughts

The above-mentioned four benefits make the laser-cutting process safer, more accurate, reliable, efficient, and cost-effective. Those improvements make laser cutting a better investment, even for steel fabrication Australia companies who previously could not justify its expense or necessary training. In turn, more facilities can experience the speed and accuracy of laser cutters in their production lines. Like with laser cutters themselves, implementing IoT systems can take time and money. However, as these advantages highlight, the results will compensate for those disruptions over time. As the industry becomes increasingly competitive and demands rise, manufacturers cannot afford to overlook IoT’s benefits.

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How to Reduce Laser Cutting Costs – Part II

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As discussed in the first part of the blog on reducing laser cutting costs, laser cutting production fits particular specifications and accurately delivers a piece’s details the first time. Many companies, small businesses, and industrial organizations tend to choose laser cutting because it produces barely perceptible edge effects from the cutting, unlike many other methods. Versatility in size and metal material is another benefit of laser cutting machinery, although these do have differences in price. In this blog, other means of diminishing expenses while using this incredible technology will be covered along with relevant considerations in this regard.

Creating Prototypes

Constructing a prototype of the fabrication design digitally, on paper or with a sturdier disposable material helps to develop a clear vision of the final product. The appearance of the design will be easier to tweak or simplify once there is a mock-up involved. Ordering the full quantity of a laser cut product without refining the desired outcome is ineffective and drains the company bank account when another order is to be placed. It is good practice to print the design from a computer onto paper with the correct measurements and spacing between the two-dimensional shapes to examine the problematic points that might cost more money in production. Digital models can also be useful since the capabilities of design software can be used to alter small-scale issues. Performing this preliminary test by heavy steel fabrication companies increases confidence in the result and reduces any costs working out kinks that are caught early.

Placing a Small Order

Once the simplified design and idea for the material have been confirmed, a small trial run of the exact supplies and design can reduce extra expenses before placing a substantial order. If certain aspects of the design are still unclear or testing of multiple metals is required, small orders will present the possibilities of several kinds of metal and the accurate implementation of your design. Any complications that arise in a small trial order will cost less than purchasing several big sheets of metal and then realizing that the specifications should have been different. Once it is evident that this metal is the fit for your intentions, the complete order can follow the small order.

Outsourcing Laser Cutting

When a project requires a precise cut that only laser cutting can accomplish, a do-it-yourself direction may be the first impulse. However, on-site laser cutting involves expensive investments in mining plant and equipment, thorough training, and inconvenient maintenance. Rather than mastering laser cutting and facing these obstacles, it is more cost-effective to outsource to experienced companies. Since laser cutting is an important fabrication technique, the equipment is substantial in size and cost. Purchasing laser cutting machinery, depending on the size and nature of your company, will likely not be reused enough to cover the costs. Necessary on-site space is infringed on, and employee training also halts the production process.

Using a specialized outside team to perform the work saves space, time, and money. The machinery also demands regular upkeep, which raises costs even higher. Safety for the work space and the condition of the products require this maintenance, but the drawbacks of further expense, repairs and effort point to another solution — outsourcing. Enlisting the help of workers skilled in this area will expedite the project and reduce overheads. They are familiar with the best practices in laser cutting, already knowledgeable about this task and able to maintain the equipment elsewhere.

Final Thoughts

Cutting down on production time and increasing intentionality in design files will reduce the cost of custom-cut pieces. Adjusting the orientation of the design if multiple pieces are manufactured will also diminish wasted metal and extra time. Overall, these techniques have the potential to ensure that the project should be finished sooner than ever before at a lower price. Hence, cutting is the way to go – for both laser and costs!

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How to Reduce Laser Cutting Costs – Part I

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Metal cutting is an important operation in most fabrication projects and laser cutting is preferred in many sectors. The precisely cut two-dimensional pieces function as machinery parts in industries from industrial baking to medicine. A common criticism of laser cutting is the cost involved during production, which can be quite high in many cases. However, many companies are unaware that their laser cutting costs, despite the production, could be significantly reduced by simple, alternate choices and communication with their laser cutting provider. So, how can the cost of laser cutting be reduced without compromising on the quality of the end deliverable? The first part of this two-part blog will focus on two techniques while looking to answer this and other questions.

Consider Sheet Metal Type and Thickness

A variety of metals can be cut, including mild steel, stainless steel, aluminum, copper, and brass. The thickness of the selected metal can alter the edge quality of the cuts, but most importantly the thickness of the metal determines how quickly the beam can cut or change due to heat induction bending services. Each of these metals has an optimal cutting thickness that displays the most stable and untainted cut possible with minimal warping or variation. If a thicker or denser metal is selected, then the time spent by the laser cutting company on the design will increase. If that metal is necessary for the project, a thick metal paired with a simple design may balance out the cost. It is important to prioritize the factors that are most important to the company and the productivity of the fabrication task in many cases.

Optimize Space by Grouping and Nesting

Laser cutting carves lines on sheet metal that are often spread out, with similar design elements and edges. However, eliminating empty segments in the design file dramatically diminishes the cost, in a similar way to avoiding double cut lines. It is efficient to reduce waste and scrap metal by increasing the usable portions of the sheet of metal. Filling the whole sheet of metal with the desired product is the ideal outcome. Wasting minuscule scrapings and debris is an inevitability most of the time, but more substantial portions of scrap metal can become profitable for the organization. Grouping and nesting are two variations of this principle.

Grouping the pieces just clusters them for efficient laser work. In general, the less distance the laser head must travel to make the next cut and the less scrap metal produced will keep more money in your pocket. This method is a simple way to create more space on the sheet of metal, and it accommodates circular cuts more easily than nesting does. Rounded lines, while expensive, may be necessary for the metal fabrication work. Positioning the shapes as close to one another as possible will be cost effective. Nesting is a more specific technique to reduce waste. This method rearranges the pieces to be cut so that they share common edges and create little excess space for optimal shapes. When complementary lines are placed together, the edge of two different shapes becomes one affordable slice. Nesting is another reason why finding the straightest lines for desired products (e.g., I-beams in structural construction) should be a priority because exact lines and angles are more likely to coincide for a common edge.

Summing Up

Laser cutting is a very technical process and it is important to understand which cost saving approach is a best-fit for a metal fabrication engagement. Understanding the types of metal used and characteristics of laser cutting deliverables helps in devising more effective cost saving strategies. While these methods are useful in the context of laser cutting jobs, there are other cost-saving techniques in laser cutting which will be discussed.

Plasma cutting of work pieces of steel structures from heavy steel plate

Laser Cutting vs. Plasma Cutting

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There are many factors which determine the metal cutting process to be used in fabrication projects such as, budget, timeline, costs, production rates, precision levels, and methods of configuring parts. In this regard, laser cutting and plasma cutting stand out as effective solutions for a range of industries. Laser cutting is a process that uses a highly concentrated, intense pulsed or continuous beam of light to cut various metals while plasma cutting uses a melting technique to deliver precise work (e.g., water tanks). So, what are the considerations to be kept in mind when choosing the best cutting method? We will look to dive deeper into this topic.

Overview of Laser and Plasma Cutting

Laser cutting utilizes laser optics and the use of computer numerical control (CNC) to heat and melt the metal while partially vaporizing it. It creates pristine, accurate cuts and works with a range of metals. This technique is often used for various industrial manufacturing applications such as manufacturing pressure vessels, as well as for engraving details, creating intricate notches, and cutting small shapes. Laser cutting is especially useful in cases when the products require precision, whether it is a complex or simple part. Advantages of laser cutting include cutting a wider variety of metals, having a standard tolerance of +/- 0.005″ and being equipped to cut thinner, more intricate metals.

In Plasma cutting, ionized gas, also known as plasma, melts the metal and then expels it. Essentially, compressed air and inert gasses like nitrogen and hydrogen shoot through a nozzle at extreme speeds to essentially blast metals such as stainless steel, copper, aluminum, steel, brass, and others with plasma. This cutting process supports applications like automotive repair, industrial construction, and hopper and tank fabrication, among others.

Choosing the Right Cutting Method

Working with a plasma cutting machine vs. a laser cutting machine can produce different solutions depending on many factors, two of which are the type and thickness of the metal. Some considerations involved when choosing the best cutting method are as follows: –

  • Cut edge quality: The quality of a part’s cut edge refers to the squareness of a product’s finished borders. Laser cutting creates a square cut while plasma cutting results in a lower edge quality level, as it is beveled.
  • Cut part precision: This precision depends on many aspects, such as heat distortion and the kerf width, as well as the size of the part vs. its programmed size. Laser cutting creates better part precision compared to the plasma technique, hence it adds value as part of custom metal fabrication techniques.
  • Cost: The cost of laser vs. plasma metal cutting takes factors such as power, abrasives, gases, consumables, and maintenance into consideration. While plasma cutting is often more cost-effective, the laser technique is faster if thick metals are not being used.
  • Production rate: The time taken to cut the metal should also be considered. Plasma cutting will be more efficient with thicker metals, while the laser method is faster and more precise with thinner resources.
  • Metal thickness: Laser cutters can cut metals up to 1 inch thick, while plasma can cut up to 5 inches or more.

The Verdict

Laser cutting is a superior option to plasma cutting when direct comparisons are made regarding precision, flexibility, production, edge quality and metal thickness. Understanding how a plasma cutting machine works compared to the laser technique indicates that the latter can help produce products with better precision and quality irrespective of the type of metal. Though laser cutting can be more expensive, it provides a lot of freedom to businesses and is the preferred cutting method of industries!

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Steel Laser Cutting – Versatility in Industry

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Cutting and manipulating various forms of metal is one of the sheet metal fabrication techniques and is used in industries such as manufacturing, fabrication, construction etc. However, there has been an increased focus on ensuring precision and flexible design results in a safe and efficient manner. This is where metal and steel laser cutting has stepped up in a big way which is highlighted by the fact that its demand in Melbourne and beyond has grown in recent years. Laser cutting machines have become prevalent in various industries, including pipe spool fabrication, due to its manifold advantages; this blog will look to discuss this in more detail.

Advantages of Laser Cutting

Laser Cutting

Laser cutting is a technology that uses a laser to cut materials, typically used for industrial manufacturing applications. It works by directing the output of a high-power laser at the material to be cut. As a result, the remaining material will either melt, burn, vaporize or blow away by a jet of gas, leaving a clean edge. Some advantages in this regard are as follows: –

  1. Increased Precision – Traditional methods can make it difficult to achieve clean, straight cuts on steel. However, with a laser cutter, one can easily perform precise cuts every single time. This means one can consistently produce higher-quality products and meet your customers’ expectations.
  2. Faster Production Times – Again, traditional metal cutting methods can take a long time to cut through thick pieces of steel. With a laser cutter, the process is much quicker, allowing one to get products out to customers faster and improve overall efficiency.
  3. Reduced Waste – It can be difficult to achieve precise cuts without leaving behind metal scraps. When one uses a laser cutter, the process is much cleaner and there is very little waste produced, saving money on overall production costs and improving the bottom line.
  4. Improved Safety – Another significant benefit of steel laser cutting is that it can help to reduce safety hazards in the workplace. By using traditional methods, there is always the potential for accidents, given the variety of moving parts. Still, with a laser cutter, the process is much more simplified and refined, creating a safer working environment and reducing the risk of injuries.
Industry Applications

Industry Applications

Metal and steel laser cutting and design can bring many benefits to many industries. This technology can help speed up production times, improve accuracy and precision and create more intricate designs. Some industries benefitting in this regard are mentioned as follows: –

  • Agricultural: Laser cutting can create highly precise parts for agricultural machinery, resulting in improved performance and longer life for each machine.
  • Contract Manufacturing and Fabrication: Many contract manufacturers currently use a metal laser cutting machine via steel fabrication to produce custom parts for their clients. This allows them to create complex shapes, designs and geometries that would otherwise be difficult or impossible to produce.
  • Military: The military also uses metal laser cutting machines to produce a variety of parts and components, including armor plates and small arms parts. The process allows better maintenance of the highest standards of quality and performance.
  • Construction: Many building organizations utilize laser steel cutting to create a variety of parts and equipment for construction projects, including everything from metal studs and beams to door and window frames.
Conclusion

Proper and precise cutting of metal and steel is intrinsic to the success of multiple projects. Laser-based cutting has a wide variety of applications and it is safer as well compared to other cutting techniques. As the fabrication world looks to streamline its operations, steel laser cutting is likely to play an important role going forward – hence, we can expect this technique to remain in the spotlight!

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