Factors For Consideration When Designing Brackets for Laser Cutting
When designing brackets that will be manufactured by laser cutting technology, factors such as material, tolerance, kerf, hole size, and others, should be considered. Brackets are used in many ways and manufactured by multiple methods and manufacturers out of multiple materials. When manufactured by laser cutting technology, brackets are precise and made to high quality standards, often for use in critical industry uses and products. There are design considerations to know that will allow the process to go as smoothly as possible and result in high quality bracket such as:
- Material Selection: Laser cutting is compatible with many materials including aluminum, stainless steel, tungsten, titanium, copper, brass, and many others. However, laser cutting is also limited to cutting thinner gauges of metal and non-metal alloys. Consult with your laser cutting service provider to see if the bracket thickness falls within these capabilities.
- Tolerance requirements: Depending on the laser technology used, the tolerance may range from +/- 0.0254mm to 0.127mm. This will affect how tight the bracket will be. If the bracket needs to fit precisely with other parts, account for tolerances by designing slightly undersized holes for press-fit assemblies or oversized holes for fasteners.
- Hole Size: Laser cutting technology can cut holes very precisely, but there is a limit on how small the holes can be made cleanly. Ask what is the smallest hole diameter that can be made through the specific material and thickness. Consider allowing for small clearance for fastening screws, bolts and rivets for easier assembly.
- Kerf: Kerf refers to the width of the material removed by the laser cut. It’s essential to factor this in when designing features that fit together. Kerf on lasers can be 0.020mm to 0.040mm for example. Adjust your design dimensions by half the kerf value to ensure parts fit correctly after cutting. For example, if the kerf is 0.040mm, add 0.020mm to each side of a hole or slot designed for a tight fit.
- Bend/Forming Angles: Different materials have minimum bend radii they can withstand without cracking. Consult your service provider on the selected material’s bend recommendations to avoid creating sharp bends that could compromise the bracket’s strength. A better solution is to add a radius to the cut area that will be bent or formed to avoid potential design issues.
Brackets laser cut for various industry applications will definitely be held to tight tolerances and quality, as long as the material and design are matched to the capabilities of the laser technology. Depending on the bracket’s design and intended material, laser systems such as ultraviolet, infrared, fiber, or CO2 technology may be used. Laser cut brackets and any additional laser cut support components, will have decades of laser technology to back them up. Though often still thought of as a new method for manufacturing, laser technology is a great method to produce brackets, shims, gaskets and countless other advanced precision components.
Post-Processing Services for Laser Cut Brackets
Post-Processing Services are extremely important for brackets and any other precision laser cut components. The fundamental reason for using a post finishing process is for the protection of the part to harsh environmental conditions like moisture, corrosion, thermal changes, and wear. Another reason is for cosmetic considerations, where the parts may be exposed and need additional coating to add color and for product enhancement. In all, post processing or post finishing is applied as the last step in manufacturing. For precision laser cut brackets, this too applies as this type of component often is used in assemblies prone to wear, exposure of chemicals, pressure and structural stress. Since there are numerous methods available, the following is an overview of post finishing applications for brackets and other components produced by precision laser cutting manufacturers. It should be noted that some finishing processing can be applied to different materials while other finishing techniques do apply to specific materials as indicated below:
| Process | Materials | Pros | Cons |
|---|---|---|---|
| Anodizing | Aluminum, Magnesium | Creates a hard, corrosion-resistant oxide layer, improves wear resistance, Enhances paint adhesion | Limited color options, not suitable for all aluminum alloys |
| Powder Coating | Steel, Aluminum | Wide variety of colors and finishes, Durable and weatherproof, Good electrical insulation properties | Requires specialized equipment, thicker coating compared to paint |
| Ekectroless Nickel Plating | Steel, Copper, Brass, Aluminum | Uniform, smooth, and corrosion-resistant coating, improves hardness and wear resistance, Good for parts with complex geometries | Relatively expensive process, Requires careful control of bath chemistry |
| Chrome Plating | Brass, Zinc Alloys, Steel, Nickel Alloys, Copper | High corrosion resistance, Decorative, reflective finish, High wear resistance | Environmentally hazardous chemicals used, can be brittle and prone to cracking |
| Electroplating | Aluminum Alloys, Nickel Alloys, copper, brass, steel | Wide range of available coatings (e.g., nickel, copper, zinc), Improves conductivity, corrosion resistance, and wear | Can be uneven on parts with complex shapes, Requires specialized equipment and disposal of electrolytes |
| Passivation | Titanium, Steel | Enhances corrosion resistance by forming a protective oxide layer, Improves surface cleanliness | Limited effect on surface finish, not a substitute for proper hard coatings |
| Acid Cleaning | Stainless Steel, Aluminum, Brass, Copper, Steel | Removes contaminants like oxides, scales, and rust, Prepares surfaces for further treatments like painting | Can be aggressive and damage delicate surfaces, not suitable for all metals |
| Tmble/Deburr | Aluminum and Aluminum Alloys, Zinc Alloys, Copper, Mild Steel, | Removes burrs and sharp edges left from machining processes, Improves aesthetics and safety | May not be suitable for very small or delicate parts, may round over sharp edges |
Forming of the bracket or bending is something that also is done post laser cutting. A bending brake or press machine is used to form the bracket along pre-defined lines. This is suitable for creating sharp angles and bends. However, to aid in the bend, laser cutting critical areas with a radius will help prevent cracking or breaking during the forming process. It is a cost-effective way to achieve the intended form of the bracket, but it can be challenging for complex and intricate parts.
Precision bracket manufacturers will recommend what finishing process will be best for your component by considering the material used and the conditions in which the brackets will be exposed to during their function. As some finishing processes may be used for several materials, knowing the pros and cons will aid in helping you make a final decision.
What Materials Are Suitable for Laser Cutting Brackets?
When it comes to creating high-quality brackets, the choice of material is crucial for ensuring durability, precision, and performance. At A-Laser, our state-of-the-art laser cutting technology is capable of working with a wide range of materials to meet your specific needs. Here are some of the most suitable materials for laser-cut brackets:
Metals
- Stainless Steel: Known for its strength and resistance to corrosion, stainless steel is ideal for applications requiring durability and a clean finish.
- Aluminum: Lightweight yet strong, aluminum is perfect for brackets used in aerospace, automotive, and electronics industries.
- Carbon Steel: Offering a great balance between strength and affordability, carbon steel is commonly used in construction and industrial applications.
Plastics
- Acrylic: With its clarity and ease of cutting, acrylic is a popular choice for aesthetically pleasing brackets used in displays and signage.
- Polycarbonate: Extremely tough and impact-resistant, polycarbonate is suitable for applications where durability is paramount.
Composites
- Fiber-Reinforced Plastics (FRP): Combining the benefits of plastics and fibers, FRP materials are excellent for high-strength, lightweight brackets in demanding environments.
What is the Minimum Thickness of Metal That Can Be Laser Cut for Brackets?
At A-Laser, our cutting-edge laser technology allows us to achieve remarkable precision and accuracy, even with the thinnest of materials. When it comes to metal brackets, we can process materials as thin as 0.08 mm. This exceptional capability opens up a world of possibilities for intricate designs and delicate components, ensuring that every bracket meets the highest standards of quality and performance.
Benefits of Cutting Thin Metals
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Precision and Detail: With the ability to cut metals as thin as 0.08 mm, we can achieve fine details and intricate patterns that are often required in specialized applications. This precision is especially beneficial for industries such as electronics, where small, detailed components are essential.
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Weight Reduction: Thin metal brackets contribute to overall weight reduction, which is crucial in industries like aerospace and automotive. By minimizing the weight without sacrificing strength, we help you achieve more efficient and lightweight designs.
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Material Efficiency: Utilizing thinner materials can lead to cost savings and reduced material waste. Our precise laser cutting ensures optimal use of materials, making your production process more sustainable and economical.
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Versatility in Applications: Thin metal brackets are versatile and can be used in a wide range of applications, from delicate electronic assemblies to intricate decorative elements. Our ability to cut such thin materials allows us to cater to diverse industry needs.
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