The laser (CO2 and fiber) cutting machine has become the ultimate cutting tool for sheet metal in recent years. It’s also one of the most rapidly evolving technologies in metal fabrication and not so long ago you’d be hard pressed to find a fiber or disk cutting laser at a custom fabrication shop. Today they’re popping up everywhere. Some figures bandied about say that 28 machines were imported into South Africa just from China, last year.
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Guenter Schmitz of TRM Supplies, a company that has specialised in the sourcing, importing, and installation of a wide range of new sheet metal machines, as well as offering service, support and repairs of the equipment, believes that the manufacturing industry in South Africa needs to be educated about the do’s and don’ts of purchasing a laser cutting machine.
“For most manufacturers, buying an industrial laser cutting machine is a major investment. It’s not just the initial price you pay, but the fact that the purchase will have a great impact on the entire manufacturing process. If the wrong equipment is chosen, you have to live with the decision for quite a long time. It is not unusual to see manufacturers keep a laser for seven to 10 years, before upgrading,” said Schmitz.
“Do you know the best way to go about purchasing a laser cutting machine? Even if you currently own one, how long ago did you buy it and what has changed since then?” continued Schmitz.
“Production managers are always on the line for costs. Whenever the economy takes a dip, the microscope comes out for a closer look at how an operation can be more efficient. For a custom fabrication shop, one way is to bring the laser cutting work that they were previously outsourcing – a big decision – in-house. What they do not realise is that along with this comes a multitude of learning curves and problems, mainly because of the lack of experience and know-how of the process.”
“But there will come that time when you have to ask yourself if it is time for the company to bring laser cutting in-house. This has to be considered even if the business relationship with the subcontractor is great. If the decision is made to bring laser cutting in-house, you may be put in a position where you need to justify why the investment needs to be made. The costs associated with subcontracting out the laser cutting are just the starting point for the justification. How much more productive will the manufacturing process be with in-house laser cutting? How does this affect lead times? From an expense standpoint, not only do you have the cost of the laser cutting machine, you have labour and consumable costs.”
“This scenario doesn’t involve a lot of risk and can work if you have some flexibility with lead times.”
“Lasers have become the true workhorses of metal fabrication, and they have never been more productive. They cut nests at unprecedented speeds, which has made material handling automation even more important. All the high cutting speed in the world may not dramatically affect overall cycle time if a laser sits idle for prolonged periods, waiting for operators to load sheets and unload parts.”
“Similar thinking also applies to edge quality. Edge quality is, of course, subjective. A fabricator will look at a laser-cut component and find that the edge quality is not very good. A welder, on the other hand, may look at the same part and see a smooth, consistent, high-quality edge. Regardless, the application requirements dictate what is considered a quality edge or not. A laser can finish a nest of components in no time flat, but what if those components need to be sent through a secondary operation?”
“To evaluate which machine is best for you, you must first understand your application and define your needs and limitations, all the while accounting for new opportunities and future goals. By doing so, you best match the system capability with your needs, allowing you to take full advantage of the productivity, versatility, and quality benefits that automated laser cutting has to offer.”
“For example, since the game-changing fiber lasers were launched they have made their mark on thin-gauge cutting and speed of cutting. Power sources on fiber machines have progressed rapidly and I believe you can even get a 20kW machine these days. All will be revealed at the forthcoming EuroBlech exhibition in Hannover, Germany in October .”
“The thickness of the gauge that a fiber laser can cut is increasing but at what cost, both in quality and price? I am sure technology will improve but at the moment you must consider CO2, plasma or waterjet cutting, depending on the gauge thickness that you operate in. Each brings its own unique strengths to the table. Which begs the question: Which process is right for you? Or do you even need to go the laser cutting route? Depending on the component volume, a stamping press, a traditional turret punch press or a high-definition plasma system may deliver the lowest cost per component.”
The pitfalls of buying cheap
“These are normal business decisions and manufacturing practice that I have explained. However, South African manufacturers are notorious for buying cheap when investing in capital equipment. It is a generalisation, but I have been around long enough to give an informed opinion. Other than monetary issues, when manufacturers offer reasons as to why they are looking at purchasing a laser cutting machine, they mention control. Ask yourself these questions to see if you fall into this category:
• How many times have we lost business because of late delivery?
• Have we ever had to reject components because of poor quality?
• How would it help our image if we had our own laser cutting capabilities?”
“Once they have said yes to these three questions and the decision to invest in a laser cutting machine is made, then they go and dig themselves in deeper by buying cheap. As a manufacturer, you have numerous sources from which to purchase a laser cutting machine. There are dealers that specialise in used equipment and original equipment manufacturers that offer state-of-the-art cutting equipment and even refurbished machines that may not have the production prowess of new machines, but can still perform much more efficiently than machines of a similar age with no rework done to them.”
“Ask the supplier questions about service availability. Today’s fiber technology does not require as much maintenance as compared to CO2, but when a machine goes down, you’ll want it back up and running as soon as possible. Find out about parts availability and delivery to fix your machine if there is a breakdown. We are working with technology and things do go wrong. This is not taking the human element into the equation. Again, a laser cutting machine that can’t cut because of a damaged part just doesn’t cut it.”
“Also be aware that laser cutting machines from OEMs that are recognisable in the industry typically have higher resale values.”
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Technical quality and backup service
“As the name suggests, CO2 laser uses a gas mixture based on carbon dioxide. The mix of CO2 and other gases, commonly nitrogen and helium, is electrically excited to create the beam. Solid-state lasers come in fiber or disk varieties and are available in the same power ranges as their CO2 counterparts. Like the CO2 variety, the name is descriptive, identifying the laser’s beam origin as a solid, either an extruded glass fiber or a small crystalline disk. Both have a rare-earth element suspended, or doped to use the industry term, in the solid matrix that is excited by diodes to emit light in in wavelengths from 900 to 1 070nm (commonly called 1µm).”
“From a facilities standpoint, solid-state lasers do not require nearly as many resources as their CO2 counterparts. Beyond the simplified beam delivery system, possibly of greater value is the modest floor space requirement. These days, fiber lasers from eight to 10kW require just 20 per cent of the floor space of CO2 lasers of similar power. Add the fiber laser’s electrical efficiency, which is three to five times better than that of CO2 lasers, and the hourly operating costs are much less than those of CO2 technology.”
“As fiber laser technology has rapidly advanced over the last several years, it can be hard to distinguish what is important when considering a high-power fiber laser. There are more things to consider than the highest kilowatt rating or the fastest advertised feed rates. Putting an entire package together for your success involves many areas of evaluation and can be challenging.”
“You have to consider the body and table, as well as the stability of these two fabricated items, the laser source, laser cutting head, air compressor, air cooling dryer and filter, the CNC system and many others. These are the standard items on a fiber laser and can be sourced easily, like many of the fiber laser manufacturers that have emerged in recent years. 15 years ago there were probably less than 20 OEM manufacturers of machines and the industry was dominated by a couple of manufacturers of fiber lasers, amplifiers and modules. The market has opened up and there are now many more manufacturers of these power systems, as well as the cutting systems. The software providers and CNC control manufacturers have exploded.”
“The end result is that virtually anybody with a bit of know-how can manufacture a fiber laser cutting machine. Who knows how many there are now? I estimate that in China there could be over 300.”
“This has led to the market being flooded with cheaper options, relatively speaking, and herein lies the problem. Everyone wants to gain market share and you now have a host of new one-man agents and representatives who have little knowledge about the process, have no back-up service, don’t carry spares and just sell on price. Daily we get calls from companies that have gone with the cheap option and their machine has broken down and now they want us to fix it. Well, their machines are still standing still.”
“Besides the power and cutting systems and the CNC controls, there are a whole host of intricate operating features that make up a laser cutting machine. These include the laser cutting heads, the nozzles, the diode modules, fiber block, digital power supplies and digital control electronics, to name a few. Then there are the safety aspects.”
“Technology in this industry over the last 25 years has seen many changes. It’s not just a case of buying from Alibaba and then plugging in and playing!”
“Big technology implementations are demanding. When investing huge sums of money in fiber laser cutting machines with elaborate material management setups, you expect an advantageous ROI. However, in the new rush to install these super-fast cutting machines, you might be discovering that navigating such an implementation project is more than you expected.”
“Like buying a CNC machine tool or your dream car, you need to be educated and informed about your capital expenditure. Deal with those that have the know-how, experience and services and resources to back them up.”
For further details contact TRM Supplies on : 011 974
As the name suggests, the CO2 laser uses a gas mixture that is based on carbon dioxide. This mixture, which usually consists of CO2, nitrogen, and helium, is electrically excited to generate the laser beam. Solid-state lasers are available in the form of fiber or disk lasers in similar power levels to their CO2 counterparts. As with the CO2 laser, the laser-active medium gives the fiber laser its name, which in this case is a glass-like or crystalline solid in the form of a fiber or a disk.
While with the CO2 laser, the laser beam is guided through a beam path using optics, the beam of the fiber laser is generated in an active fiber and guided to the machine’s cutting head via a transport fiber. One of the key differences, apart from the laser medium as such, is its wavelength: With a fiber laser the laser wavelength is around 1µm and with a CO2 laser 10µm. The fiber laser’s shorter wavelength results in a higher absorption rate when cutting steel, stainless steel, and aluminum. A higher absorption rate means lower heat generation in the material that is being processed, which is, of course, a positive attribute.
CO2 technology is ideal for all-rounders who process a wide variety of materials and thick metal sheets. A fiber laser cutting system, on the other hand, is capable of processing the thin to thick range of sheet thicknesses with materials ranging from steel, stainless steel, and aluminum, right through to non-ferrous metals (copper and brass).
The advantage of the CO2 laser is its superior cutting quality in thick steel (mild steel). The fiber laser, on the other hand, offers high cutting speeds and lower operating costs per hour. Fiber lasers require nowhere near as much energy as CO2 lasers, and their electrical efficiency is up to 5 times higher. What is more, the beam path of fiber lasers is simpler. Another big bonus is the more compact footprint: A fiber laser system with 8 to 10 kW laser power requires only about one fifth of the floor space of a CO2 laser system of comparable power.
Fiber laser technology has advanced rapidly in recent years. However, it is important to consider more factors than just the laser power and cutting speeds. Success in the sheet metal processing sector is dependent on an entire array of diverse and individual factors, all of which revolve around the core question: What is the optimal workflow? Even the most high-performance machine can only be cost-effective if its potential is fully exploited.
The factors vary enormously. In order to be able to evaluate which machine is best suited, one must first understand the intended application and define not only its requirements, but also its limits. One should also consider potential new objectives on the horizon and other options. After all, the purchase of a laser cutting system represents a major investment, and the decision concerns not just the machine itself. The purchase has an impact on the entire manufacturing process, covering everything from manpower, service and maintenance, consumables, right through to know-how.
Other factors are also involved: The fiber laser allows companies to increase the speed of a single process step. However, this may make it necessary to automate loading and unloading, since otherwise the machine will frequently be idle because its operators cannot keep up.
The prime objective is clear: Reduce costs while increasing product quality and productivity. Achieving this objective with the purchase of a new system requires know-how that may not yet be available within the company. The capacity and performance of the system must correspond to the needs. If you invest a significant sum in a fiber laser cutting system in combination with complex material management solutions, you naturally expect to achieve a favorable ROI.
15 years ago, there were perhaps no more than 20 laser cutting machine OEMs, and the industry was dominated by a handful of leading suppliers. In the meantime, however, the market has opened up, and today, there are a multitude laser cutting machine manufacturers on the market. The number of suppliers of other components, such as software and CNC controls, has also increased dramatically, with the result that virtually anyone with a modicum of know-how can now produce a fiber laser cutting machine.
This development has resulted in the market being flooded with cheap equipment, and this is precisely where the problem lies: Sheet metal processing companies are faced with a large number of new suppliers who have little process knowledge, do not guarantee spare parts availability, and do not offer any customer services, because their only goal is to sell at low costs in order to increase their own market share. This often results in the fact being overlooked that rather than being a plug-and-play solution, a laser cutting system only works when countless components interact flawlessly.
The industry has experienced significant technological advancements over the past 25 years – and major technological rollouts are always challenging.
Very important! Current fiber technology does not require the same level of maintenance as CO2 technology, but if a machine breaks down, it is imperative to get it back up and running as soon as possible.
CO2 lasers require extensive and time-consuming maintenance. It is not unusual for a service technician to be on site for up to three straight days. CO2 lasers require servicing every 12 months or every 2,000 operating hours. With increasing service life, the overhauls required (for example of the resonator, optical components, and beam path) increase.
In comparison, the maintenance of fiber laser machines is considerably less time and cost intensive. A fiber laser has fewer parts that require maintenance, which translates into real cost and time savings. Thus, the time required for maintenance and inspection of fiber lasers is significantly reduced and usually takes just a few hours.
However, both laser technologies require the service intervals to be adapted in the event of shift operation. Naturally, a laser cutting machine that is in operation 24/7 requires more frequent overhauls. This has an impact on both the maintenance costs and the downtime for servicing.
At the end of the day, the choice of a laser cutting machine should be based not only on the purchase price, but also on the total cost of ownership, calculated over the machine’s entire service life. Maintenance and energy costs as well as machine downtime should definitely be factored in. The energy costs, which can make up a considerable portion of the total annual expenses, are significantly lower with fiber lasers.
For all these reasons, potential buyers should obtain information about the availability and supply of spare parts, so their machine can be promptly repaired in the event of a breakdown. They should also clarify whether the supplier has a service technician stationed nearby who speaks their language.
When you use sophisticated, highly complex technologies, you have to reckon with hiccups. A laser cutting machine that is unable to cut because of a single damaged part is simply not an asset for the customer.
There is no simple answer to this question, because it depends on so many factors. As previously mentioned, the demands you place on the laser cutting machine play a key role. This has an impact on the size and capacity of the system. The peripheral equipment is also an aspect that must be considered: For example, do the workflows require an automatic loading and unloading system?
If you decide to buy a laser cutting machine, you should not only focus on the costs of the purchase itself, but also evaluate the total cost of ownership, calculated over the machine’s entire service life, including maintenance costs and machine downtime.
In addition, your staff’s current technical skills and their training needs must also be addressed.
Companies that do not consider these factors often make decisions that can have dire and long-lasting consequences: They choose a cheap system. Poor quality, the lack of know-how and experience, no spare parts, and poor service can, in the worst case, rapidly shut down the entire production process.
An integrated concept that takes into account all the points mentioned above is absolutely essential. In the final analysis, it is a matter of working in partnership to find the optimal solution for you. Because only a satisfied customer is a good customer.
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