A recurring debate exists within the realm of production:
What approach should be taken when producing parts that require structural integrity along with precision in geometric form? The response to this issue appears to lie in the merging of these two processes.
Laser cutting, along with fabrication and precision CNC machining, represents the most effective means of addressing both ends of this spectrum simultaneously.
Two Technologies, One Goal
Before we delve into how they complement each other, let us first take a look at their respective capabilities.
CNC machining refers to subtractive manufacturing processes whereby material is removed from a block of raw material by milling, drilling, or lathe processes controlled by computers. It excels in forming precise features such as bores, threads, slots, chamfers, and complex 3D profiles. Dimensional precision is excellent, with tolerances as small as ±0.01mm achievable.
In contrast, laser cutting involves cutting sheet metal by focusing a beam of light through the material. It is a very rapid process with accurate cuts and capable of cutting intricate 2D profiles in sheet metal. When combined with other fabrications processes such as bending and welding, it results in parts becoming structural components.
When the two processes come together, we can create parts which begin with laser cutting of flat stock material, then formed into 3D components via bending, welding, etc., then have CNC machining applied to achieve specific dimensions for critical areas.
Why Fabrication and Laser Cutting Work So Well Before CNC
Speed and Material Efficiency
Lasers cut much more quickly than machine tools for cutting flat profiles. The less work that needs to be done on a part – whether it's a bracket, an enclosure panel, or even a baseplate – by cutting sheets versus milling solid stock, the better off you'll be.
Design Flexibility
Laser cutting can help design complex shapes such as curves, slots, notches, and other intricate shapes, which take a lot more time to do by milling. Therefore, the design freedom is increased because they need not be concerned with their designs being manufactured by machines.
Clean Starting Points for Machining
The edges created using the laser cutter are sharp and clean. When a particular piece moves on to the CNC machine after being cut by a laser and fabricated, its geometry is consistent, making things easier for machining.
Where CNC Machining Takes Over
After fabrication is completed, the following operations can be carried out by the CNC machine, operations which laser cutting cannot perform:
Creation of precisely pitched and precisely threaded holes
Creation of bores whose specifications include precision roundness and surface finish
Precision machining of critical mating surfaces that need to fit without any clearance between two pieces
Machining to final critical dimensions of features
This stage in the workflow process is very important. The personnel doing both these operations have to be aware of how fabrication distortion through welding may impact machining.
Conclusion
Using the combination of CNC machining, fabrication and laser cutting isn’t just convenient; it is a smart manufacturing technique that fills each other’s gaps and creates products that are economical and precise.
FAQs
Can you handle both laser cutting and CNC machining in-house?
Yes. Genesis-MFG offers an integrated service that covers fabrication, laser cutting, and precision CNC machines under one roof in Sharjah, UAE.
What sheet metal thicknesses can laser cutting handle?
This depends on the material and equipment, but common ranges cover thin gauge sheet up to thicker plate for structural applications. We'll advise based on your specific design.
Is laser cutting suitable for aluminum and stainless steel?
Absolutely. Laser cutting works well on mild steel, stainless steel, aluminum, and other metals commonly used in industrial fabrication.
How do I get started with a multi-process component project?
Simply reach out to our team with your drawings, models, or samples. We'll review the design and recommend the most efficient combination of processes to produce your parts.
Comments