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Laser cutting is a revolutionary technology that uses concentrated beams of light to cut through materials with unmatched precision and efficiency. Whether you're working with metals, plastics, or even wood, laser cutting machines offer a versatile solution for creating intricate designs and high-quality finishes.
But how does a laser cutting machine work? This article dives deep into the mechanics behind this advanced process, explaining everything from the principles of laser generation to the step-by-step cutting procedure.
Understanding how these laser machines operate not only highlights their value in modern manufacturing but also unlocks their potential for innovation across industries. Let’s explore the fascinating world of laser cutting technology!
Laser (Light Amplification by Stimulated Emission of Radiation) is a special light source with the following unique characteristics:
Compared with ordinary light sources, lasers have higher brightness, stronger directionality, and better coherence, making them ideal tools for industrial applications such as industrial cutting and welding.
How laser cutting works? Laser cutting is a technology that uses a laser to vaporize materials, resulting in a cut edge. The laser processing begins with a laser source (or laser generator), such as a CO2, Nd:YAG, or fiber laser, which generates a highly focused beam of light. The focused laser beam is directed to the workpiece material, where it is absorbed and converted into thermal energy.
Laser cutting uses light energy converted into heat energy to locally heat and cut materials. Its core working mechanism includes the following aspects:
When a high-intensity laser beam is irradiated onto the surface of a material, its energy is absorbed and rapidly converted into heat energy, causing the following physical changes in the material:
This combination of focused energy and precision control allows the laser cutting to deliver exceptional results for a wide range of applications.
Photons in the laser beam carry energy, and when they interact with particles on the surface of the material, they transfer their kinetic energy to the particles, causing intense vibrations, which in turn generate heat. This process rapidly raises the local temperature, reaching the melting or vaporization point of the material.
During the cutting process, the following physical phenomena work together to complete the machining:
The laser source is the core of the machine, generating the laser beam used for cutting. Different types of lasers used in laser cutting have unique working principles, advantages, and disadvantages:
| Type | Wavelength | Power Range | Applicable Materials | Photoelectric Efficiency |
| CO₂ Laser | 10.6 μm | 1-15 kW (up to 50 kW) | Non-metal/thin metal sheets | 10%-20% |
| Fiber Laser | 1.06 μm | 1-12 kW (up to 30 kW) | Highly reflective metals (e.g., aluminum, copper, brass) | 30%-35% |
| Nd:YAG Laser | 1.06 μm | 50 W-7 kW | Precision micromachining and specialized applications | 1%-4% |
The laser beam must be transmitted from the source to the workpiece with minimal energy loss and focused precisely on the cutting zone.
The control system ensures precise operation by managing motion, power, and cutting parameters.
The cutting head houses the focusing lens and nozzle, which play crucial roles in directing the laser beam and auxiliary gas.
Operators interact with the machine through control software that manages design input, parameter settings, and real-time monitoring.
Put the materials to be cut into the laser cutting machine, and adjust the location according to the types and thickness of the material. This setting includes the power of the laser, the movement speed of the laser, and the focus of the laser beam.
The best optimal parameter depends on the model of the laser cutting machine and the types of materials being cut.
After setting all the contents and beginning to operate, you can start the cutting and engraving. It all begins with laser resource, which generates solid and consistent light.
The laser resource origins from a laser resonator, which sends a solid beam to the cutting head through the mirror system. Inside the cutting head, the laser is focused by the lens and reduced to a skinny, concentrated beam.
This beam can be guided on the material along the path specified by digital to cut or raster the raw material. By the way, if you use sunlight and a magnifying glass to start a fire, you will be more familiar with the working principle.
When the light moves along the path, it will melt, burn or vaporize the material, resulting in precise cutting and engraving.
The laser-cutting machine can also blow away the extra materials via a gas jet. The cutting head is usually fixed on the gantry, which is a mechanical system.
A belt or chain usually drives this system and allows for cutting head to move accurately in a specific rectangle region (the size of working bed).
The gantry allows the cutting head to move back and forth on the the workpiece to cut precisely at any place on the bed. The laser should focus on the material being cut to achieve the best cutting state.
All the laser cutting machines need to focus the program before cutting to ensure an excellent laser-cutting effect. Apart from the function of the laser itself, the laser cutting machine also is equipped with assistant gas.
This gas is jetted from the cutting head in the cutting process and assists in cooling the materials and cleaning the melted metals. As a consequence, the laser cutting machine can not only provide accurate cutting but also can keep the cutting surface clean and smooth.
Laser cutting offers versatility and precision across a wide range of materials, including metals and non-metals. Below is an in-depth exploration of the characteristics, laser settings, and considerations for each category.
Recommended power settings vary by material thickness:
| Material Thickness | Power Range (watts) |
| Thin sheets (up to 1 mm) | 500–1000 |
| Medium thickness (1–5 mm) | 1000–2000 |
| Thick materials (over 5 mm) | 2000–4000 |
| Metal Type | Characteristics | Challenges |
| Carbon Steel | Cost-effective, strong, easy to cut. | Prone to rust; requires protective coatings |
| Stainless Steel | Corrosion-resistant, durable. | Reflective surface requires careful settings |
| Aluminum | Lightweight, corrosion-resistant. | High reflectivity; risk of warping during cutting |
| Copper & Brass | Excellent thermal and electrical conductivity. | Reflective surfaces require higher power |
| Titanium & Nickel | High strength and corrosion resistance; used in aerospace and medical applications. | Expensive; requires precise control |
Non-metal materials exhibit unique properties that make them suitable for various applications:
| Material Type | Power (%) | Speed (mm/s) | Focus Position |
| Wood | 30–50% | 50–150 | 1–2 mm above material |
| Acrylic | 40–70% | 100–200 | Optimal focus ensures polished edges |
| Fabric/Textiles | 30–50% | 50–150 | Prevent fraying with precise focus |
| Paper/Cardboard | 10–30% | 200–400 | Avoid burning with lower power |
Laser cutting for metals has the advantage over plasma cutting of being more precise. As the powerful laser makes contact with the material, it generates heat that melts or vaporizes the surface. Based on the types of assistant gas, there are four main types of laser cutting techniques:
In infusion cutting, the assistant gas does not assist in melting material but works only after the laser has melted the material. Inert gas (nitrogen) is usually regarded as an assistant gas for cutting.
Pressurized assist gas blows molten metal out of the kerf, increasing the cutting speed and reducing the laser power required to cut material. Fusion cutting is used for cutting metal. This technique is also named melting and blow cutting.
The assistant gas (oxygen) participates in the material’s burning and melting in flame cutting. The laser beam heats the material, and oxygen reacts with heated materials, resulting in flame. This increases the power input to the material and benefits the laser beam in cutting material.
At the same time, I am using the high-pressure oxygen flow to blow away melted metal, thus realizing cutting. Flame cutting is usually used for thick carbon steel materials. Due to the reaction between oxygen and heated materials, this technique is also called reactive cutting.
Sublimation cutting will show up when thin materials (such as foils and fabrics) are cut under no assistant gas. In this method, a laser beam vaporizes the material directly rather than melting it.
The high energy can evaporate the material on the focus, thus forming a narrow cut. This kind of cutting is also called vaporization cutting.
Impact cutting is used for materials that are difficult to cut with continuous laser beams. It involves a fast pulse laser beam on the material's surface to form overlapping holes.
Impact cutting usually is applied for cutting brittle materials such as ceramics and glass. Different kinds of lasers should be based on the actual application and materials. For example, the CO2 laser is usually used for cutting various materials, and the fiber laser is generally applied for metal.
The laser cutting machine utilizes the synergistic effect of high energy laser beam and assistant gas to fulfill the accuracy and high-efficiency cutting of metal materials.
Accepting training and knowledge when operating the laser cutting machine is vital. For example, wearing protective goggles, avoiding direct eye contact with the laser beam, and ensuring good ventilation. Thus safety and best results can be achieved. Also, the machine requires regular maintenance to keep it working efficiently.
The laser cutting machine adopts high-power lasers to cut accurately and efficiently in many fields. Various cutting techniques, such as flame and fusion, are becoming increasingly indispensable for modern manufacturing and laser technology.
ADH's laser cutting machines offer unparalleled precision and efficiency in the metal cutting industry, sheet metal fabrication, and various mechanical engineering applications.
Act now and transform your production process today! You can browse our products to choose the suitable machine or consult our sales to learn detailed information.
A laser cutter is a type of CNC (Computer Numerical Controlled) machine, meaning that it is controlled via a computer. A designer can design something in some sort of design software, and then send it to a laser cutter to have it cut out automatically, with just the push of a button.
Materials with Toxic Emissions. Chlorinated Plastics (e.g., PVC and Vinyl): Cutting PVC releases chlorine gas, which is toxic to humans and can corrode the components of the laser cutter. ABS Plastic: It emits cyanide fumes when lasered. And it usually comes with melting results rather than a clean cut.
The maximum cutting thickness of different materials with a 2000W fiber laser cutting machine is as follows: the maximum thickness of carbon steel is 20 mm; the maximum thickness of stainless steel is 8 mm; the maximum thickness of aluminum is 6 mm; the maximum thickness of copper is 4 mm.