Laser cutting is one of the most versatile and widely adopted technologies in modern manufacturing, thanks to its unique ability to process a vast range of materials with exceptional speed and precision. The numerous advantages of laser cutting, such as its non-contact nature and high-quality finish, have made it an indispensable tool. The uses of laser cutting span nearly every industry, from fabricating large-scale industrial components to creating microscopic features on medical implants and electronics.
The technology used in this type of precision laser material processing is flexible, allowing it to be adapted to an ever-growing list of materials and challenges. This article explores the most common applications of laser cutting, the types of materials it can process and where the technology meets its limits.
The applications of laser cutting are incredibly diverse. Its ability to create complex shapes from a digital design without expensive tooling makes it ideal for both rapid prototyping and high-volume production. Here are some of the most common applications:
Sheet Metal Fabrication: This is a primary application, where lasers cut parts from steel, aluminum, and other alloys for the automotive, aerospace and general manufacturing industries.
Medical Device Manufacturing: Lasers are used to cut the intricate filigree patterns of cardiovascular stents, as well as components for surgical tools and other implants where precision and a burr-free edge are critical.
Electronics: In the electronics industry, lasers perform high-precision tasks like cutting flexible circuits, singulating (depaneling) printed circuit boards and scribing silicon wafers.
Textiles and Fabrics: Laser cutting is used to create patterns in everything from clothing and leather goods to industrial textiles like airbags and sailcloth, often sealing the edges to prevent fraying.
Signage and Architecture: Lasers are used to cut custom signs, decorative panels, and architectural models from materials like acrylic, wood and metal.
Yes, laser cutting is an excellent method for processing many types of plastics and polymers. Because it's a non-contact process, it avoids the mechanical stress that can cause cracking or deformation in brittle or soft plastics. The focused heat of the laser creates a clean, often flame-polished edge, reducing the need for secondary finishing steps.
Different plastics react differently to laser energy, but common materials that are well-suited for laser cutting include:
Acrylic (PMMA): One of the most popular materials for laser cutting, it produces a beautifully clear, flame-polished edge.
Polyimide: This material is used in flexible circuits, and lasers are the preferred method for cutting its complex patterns.
Polyester (Mylar) and Polycarbonate: Often cut in thin film and sheet form for overlays, gaskets and stencils.
ABS and Styrene: Commonly used for prototyping and modeling.
It's important to note that some plastics, like polyvinyl chloride (PVC) should not be laser cut as they release harmful corrosive fumes.
The type of laser used for cutting metal is primarily determined by the material type, its thickness and the desired quality. Today, fiber lasers are the most common and versatile choice for metal cutting. Their ~1 µm wavelength is highly absorbed by most metals, and their excellent beam quality allows for high power density, resulting in fast cutting speeds and the ability to process reflective materials like copper and brass.
For specific applications, other lasers are also used:
CO₂ lasers have historically been the workhorse for cutting thick-section steel but are less efficient than fiber lasers.
Ultrafast lasers (picosecond or femtosecond) are used for "cold" ablation cutting of thin metal foils with the absolute highest precision and no heat-affected zone, which is critical in medical and electronics applications.
When identifying the best galvo scanner laser for metal, the answer depends on the task. For cutting intricate patterns in thin metal foils (like for stents), an ultrafast or fiber laser paired with a high-speed galvo scanner is the ideal solution.
While the list of what materials can be laser cut is long, there are some materials that are either difficult or impossible to process with a standard laser:
Highly Reflective Metals: Metals like polished silver, gold and copper can be challenging because their surfaces reflect most of the laser's energy, especially at the wavelengths of common industrial lasers. While modern fiber lasers have made this much easier, it can still be difficult.
Certain Plastics and Foams: Materials like polyvinyl chloride (PVC) and certain foams release hazardous and corrosive gases (like chlorine gas) when heated, which can damage the laser cutting system and pose a health risk to operators.
Composite Materials: Layered composites with different materials (like carbon fiber with an epoxy resin) can be tricky. The different layers may absorb energy and react to heat differently, leading to delamination, burning of the resin or a poor-quality cut edge. Specialized laser parameters and techniques are often required to process these materials successfully.