Benefits of Laser Cutting Brackets Over Other Methods
Laser cutting offers multiple benefits like speed of manufacturing, material compatibility, and precision over other methods. When laser cutting manufacturers are asked to produce brackets, these mentioned benefits along with others, do apply. Laser cutting is still a big mystery to many seeking a precision manufacturing process. Precision is a key term in this technology, as even the simplest form of component will have a high degree of precision done during the laser cutting process. Lasers come in different system types and technologies like fiber, ultraviolet, CO2 and infrared. Each has its own technological advantage, but they all have unique characterized benefits by using laser technology. For consideration the following are some of the benefits to use of laser technology:
| Feature | Laser Cutting | Die-Cutting | Stamping | CNC Machining | Waterjet |
|---|---|---|---|---|---|
| Speed | High-Excels on thinner material gauges- hard to handle and process by other methods | High for large quantities, slower for setup | High for large quantities, slower for setup | Medium to low, depending on complexity | Medium to low, depending on material thickness |
| Precision | Excellent, can achieve tolerances of 0.0127mm to 0.0254mm | Good for consistent shapes, limited to die geometry. Tolerances of 0.127mm to 0.254mm | Good for consistent shapes, limited to die geometry. Standard tolerance 0.127mm to 0.381mm | Excellent, can achieve high tolerances. Tolerances of 0.0254mm to 0.127mm | Good for complex shapes, less precise than laser. Tolerance of 0.050mm to 0.127mm |
| Material Compatibility | Wide range of materials, including metals, plastics, ceramics, polyimides, brazing materials, and wood | Limited to sheet materials, often paper or thin metals | Limited to sheet metals, often ductile materials | Wide range of metal alloys and some plastics but can be inefficient for some. Good for thicker materials 3,4 and 5 axis | Wide range of metal alloys, but can be expensive and slow |
| Waste | Minimal, as cutting is precise and material utilization is good | Can be high due to material scrap and die wear | Can be high due to material scrap and die wear | Can be high depending on material removal | Can be high due to water and abrasive consumption |
| R&D -Production | Rapid prototyping, design flexibility of 2D profiles, quick production setup | Slow prototyping, limited design flexibility, long setup | Slow prototyping, limited design flexibility, long setup times | Flexible design capabilities, moderate setup | Flexible design capabilities, moderate setup times |
Though the table shows some good benefits to using laser cutting technology for brackets or other precision components, there are limitations to laser technology like the thickness of the materials that can be processed and cost considerations. As bracket designs and their intended functions will vary greatly, determination if laser cutting methods can be done with further research and communication with selected service providers. It is the best way to learn of the potential challenges and potential benefits by speaking directly to the experts in each field. That is, in my perspective, the satisfaction we can achieve by helping with a project even if it is not within one’s manufacturing capacity. The result is to develop that business relationship with you, the customer, that will pay back with goodwill and perhaps future business opportunities.