Fiber laser cutting or CO2 laser cutting: Which is better for cutting metal?
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This question has sparked years of conversation and discussion among manufacturing experts. Some insist CO2 is the better technology, while others would never go back to CO2 after experiencing the innovations of fiber laser cutters.
Is there a definite right answer? Most laser manufacturers offer both CO2 and fiber laser cutting systems, but in recent years fiber laser cutting has really made a name for itself. The truth is customers must carefully analyze their operational capabilities, power sources, performance requirements, and material types and thickness before investing in the laser cutting system that works best for them.
Fiber laser cutting, or solid-state laser technology, is newer to manufacturing and metalworking, making its debut only about 15 years ago. CO2 laser cutters have been around for almost a half-century, but fiber laser technology burst onto the scene and impacted the entire sheet metal fabrication industry with its prodigious power and speed.
In just five years, fiber lasers had already achieved the 4kW cutting threshold that took CO2 lasers about two decades to reach. Today, fiber lasers have achieved up to 12kW and beyond. Contrary to popular belief, speed isn’t everything, but it is a testament to how far laser cutting technology has evolved.
A fiber laser cutter delivers an extremely intense, amplified beam to the cutting head of the laser machine. The beam is readily absorbed into the material and not reflected. The fiber receives the light source from the resonator of the laser cutting machine and brings it to the CNC-controlled cutting head.
Fiber lasers can cut metal that is more than one inch thick, but optimal performance comes on cutting metal that is 1/2 inch thick or less. For processing stainless steel, aluminum, brass or copper, fiber laser cutters are becoming known as the fastest and most economical option.
Fiber laser cutters work when nitrogen or oxygen is employed as an assist gas. Nitrogen can expel molten material as fast as it is melted. Using oxygen as an assist gas creates a wider channel to expel the molten steel. The wider beam profile also produces faster cutting speeds and increased cut edge quality on thicker materials.
So what are the advantages? Fiber laser cutters have a long list:
Taken all together – greater throughput, lower operational costs, and less maintenance – these advantages can mean greater productivity, lower cost per part, higher potential profit margins, and shorter return on investment time.
On a CO2 laser cutter, light is produced when electricity flows through a gas-filled tube with mirrors at both ends. One mirror is fully reflective while the other one lets some light come through. These mirrors guide the laser beam into the material to be cut. The gas is carbon dioxide as the name suggests.
CO2 laser cutters can cut all types and thicknesses of steel and metal: Mild steel, stainless steel, aluminum, as well as plastic, tile, marble, and stone.
CO2 laser cutters offer several advantages:
The downside is CO2 lasers cost more to operate and maintain. Aside from the consumables, and gasses required to keep the beam path delivery system functioning optimally, power costs can be up to 70% higher.
Each laser cutting system has its strengths and weaknesses, as well as compelling arguments for specific uses when cutting various metals like aluminum, stainless steel, and steel.
Which laser cutter is right for you comes down to usage. Which systems best fit your operation and application? How much faster and how much more cost-effective are your parts going to be produced? The answer comes only after a careful analysis of operation costs, throughput, maintenance expenses, and costs.
No matter what laser cutting system you decide to use, Mid Atlantic Machinery supplies high-quality, high-performing Trumpf fiber laser cutters and CO2 laser cutters to cut whatever metal you utilize and create the precision parts that satisfy your customers’ needs.
The fiber laser cutting and CO2 laser cutting systems we offer provide the innovative features you expect from an industry-leading manufacturer of metal fabricating equipment:
Mid Atlantic Machinery has served fabricators, manufacturers, and related businesses with the latest in fabrication and machine tool technology for more than a quarter of a century. We represent top equipment brands throughout the Mid Atlantic region and New England. From Maryland to Maine, we’re a one-call resource for the latest fabrication technology. Fill out a Contact form to get in touch today!
Most cutting lasers fall into either the CO2 or fiber laser categories. Each technique has strengths and weaknesses that must be evaluated when selecting equipment for any particular task. Fiber lasers can cut almost all materials and do so 3 to 5 times quicker than other styles. However, they work best on sheet materials 5 mm or thinner. In the transition range from 5 to 20 mm thickness, the advantages of fiber lasers are less marked and the capabilities of CO2 lasers can be beneficial. Above 20 mm, fiber lasers rapidly lose their value. Materials like steel with thicknesses of up to 100 mm typically need oxygen-assisted CO2 lasers. This article seeks to explain the differences between CO2 lasers vs. fiber lasers that are important to know when specifying services or purchasing equipment.
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A CO2 laser exploits the electrically induced vibration of carbon dioxide molecules to trigger the rapid emission of photons. It works by applying an electric field either along or across a gas-filled tube containing 10-20% each of N2 and CO2 along with trace hydrogen and xenon. The remainder of the tube is filled with helium. The electric field causes the N2 molecules to vibrate. Nitrogen, being homonuclear, cannot lose energy by photon emission, so the vibration of N2 molecules increases rapidly. N2 and CO2 have very similar natural vibration frequencies, so the energy is transferred to the CO2 by sympathetic oscillation. They then impact helium atoms, altering their vibrational mode and heating the helium. Vibrational mode transition releases a photon, so it generates light. CO2 has three vibrational modes, giving it two potential transitions. CO2 lasers can thus emit two primary frequencies of laser light (if they are built to allow for both). The ends of the tube are capped with Brewster mirrors: one half-silvered and the other fully silvered. The light passage out from the half-silver mirror is collimated and can be reflected and refracted to direct and shape the beam.
CO2 lasers put out infrared energy. It’s a relatively low-frequency electromagnetic wave but has better effective power than many other wavelengths. Thus, these lasers have some significant advantages:
Some variants, like RF gas flow CO2 slab lasers, are improvements on the basic type. These enhancements improve output, product life, and efficiency.
For more information, see our guide on CO2 Laser.
Fiber lasers are monolithic in construction and built around a specialized optical fiber. Light is introduced into the optical fiber generator, usually from a small solid-state laser, and the optical fiber doping acts as an amplifier. A fiber laser consists of a series of devices that function in sequence to create laser light. It works with a pump source (laser diode) that emits light captured by a ‘reflective’ clad fiber optic guide that retains virtually all of the pump source light. Light leaves the guide and enters the laser cavity. The pump source light hits rare-earth dopants inside that cavity. This process generates more light through a cyclic process of electron excitation and relaxation. The dopant element has a specific frequency of emission, which defines the frequency of the resulting laser light.
Ytterbium dopant emits at nm and is the type generally used in laser cutting. The internally emitted light hits a series of fiber-Bragg gratings which act as internal reflectors, keeping the light within the laser cavity. The second type of fiber Bragg grating acts as a ‘gate.’ It allows a portion of the light to pass while reflecting most back into the cavity. Laser light leaves the cavity through another fiber guide, by now highly collimated (i.e. very parallel). The beam then passes through a short-focal-length lens and is concentrated to the shape and diameter required for a cutting application.
As a specialist group of solid-state lasers, fiber devices offer significant benefits over other technologies, including:
CO2 lasers consume considerably more power than fiber lasers for the same energy output, so their operational power costs are much higher. The up-front cost of CO2 lasers is also considerably lower than that of equivalent fiber lasers. The most expensive fiber laser-equipped cutting machines will commonly be 5 to 10 times the price of their CO2 equivalent. Fiber lasers provide higher cut precision than CO2. They have 10 times the working life of CO2 devices, often reported as 25,000 working hours. Refurbishing services for fiber devices are also easy to access.
CO2 lasers are well suited to cutting many nonmetallic materials and nonferrous metals. Examples are acrylic, melamine, mother of pearl, paper, mylar, plastic, rubber, non-resin wood, Delrin® (POM), cloth, Corian®, cork, fabric, fiberglass, leather, dense card, and plywood.
Fiber lasers, on the other hand, are less specific in material applications and will work with most materials, although they’re best suited to cuts of 20 mm or less. Examples of materials are metals (including highly reflective types such as stainless steel), glass, acrylic (PMMA), POM, paper, dense card, and most foams.
CO2 lasers can be made in powers ranging from a few dozen watts up to around 100 kW. High-powered devices produce poor-quality beams unless they are very long. Because of their very low efficiency (5-10%), larger devices need considerable cooling capacity, increasing size even further.
Low-power ytterbium-doped fiber lasers fall in the same ranges as CO2 ones, but the type’s upper power limit approaches 1 MW (for very large, very expensive devices). High operational efficiency (often above 90%) results in a limited need for cooling, especially in smaller devices.
The difference in wavelength between a CO2 laser and a fiber laser is around a factor of 10. CO2 lasers produce light at 10.6 µm (or 9.6 µm for some types), whereas ytterbium-doped fiber lasers emit at nm (or 1.064 µm).
In terms of up-front cost, fiber lasers are more expensive per watt of power than CO2 devices. However, they typically have up to 10 times the functional life expectancy of CO2 devices, so they’re usually the better long-term option.
In terms of operational power use, CO2 lasers are around 5 to 10% efficient — meaning they draw 10 to 20 times as much electricity as they emit in the form of laser light. This compares very poorly with fiber lasers, which generally offer over 90% efficiency (i.e. only 10% of their power fails to get converted into laser light.
CO2 lasers can cut most materials and find applications in all industries, including medical, military, communications, and other manufacturing industries. In particular, they are the best option for the processing of thicker (10-20 mm or more) metal plates. Operators often add oxygen assist to speed up the cutting of a 100 mm steel plate.
Fiber lasers are more prevalent in high-precision and high-value market sectors such as telecommunications, medical, material processing, automotive, and electronics. Fiber laser cutting machines can cut most materials but function best with difficult-to-cut and reflective metals like titanium, brass, and aluminum.
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