Laser cutting is one of common manufacturing methods nowadays. It is widely used from consumer electronics enclosures and automotive components to battery, medical devices, and aerospace parts. This article will introduce laser cutting from key aspects including definition, ideal materials, functions, and applications.
What Does Laser Cutting Mean in Engineering?
Laser cutting is an automated machining method used to cut, etch, or engrave materials with a concentrated and high-power laser beam. In 2026, laser cutting is not a processing method only, it is a system that has 5 core components: laser source, optical system, motion and control system, process system, and data system.
Types Laser Cutting
Due to different properties of materials, requirements and costs, laser cutting has developed various types including CO₂ laser cutting, fiber laser cutting, disk laser cutting, and ultrafast lasers. Now let us explore their charming features.
1. CO₂ Laser Cutting
Suitable for non-metallic materials (acrylic, wood, leather), thin carbon steel and stainless steel sheets, and parts requiring high cut surface finish with moderate precision. Its engineering characteristics include mature technology and robust maintenance systems, making it irreplaceable in non-metallic processing.
2. Fiber Laser Cutting
Fiber laser cutting is the mainstream choice in industrial applications, which is suitable for metals including carbon steel, stainless steel, aluminum alloys, and titanium alloys. It is ideal for stable and mass production.
By 2026, fiber laser cutting can automatically switch beam mode between thick plate cutting and precision cutting, and process highly reflective materials. It is obvious that fiber laser cutting has advantages including high speed, lowest cost, and high automation.
3. Disk Laser Cutting
Disk lasers is ideal for cutting plates 30-50 mm thick and above, steel with high strength, structural components, and parts requiring exceptional cut perpendicularity and stability. It benefits include providing stable beams and controllable heat-affected zones. That is why disk laser cutting is usually used in manufacturing heavy equipment, energy facilities, and ship structural components.
4. Femtosecond Lasers
Ultrafast lasers are suitable for brittle materials (glass, ceramics, sapphire), medical devices, microstructures, and functional cut processing. Its core advantage is its cold processing mechanism that can provide high-quality cut edges, which is favorable for fatige performance and microcrack resistance.
What are the Advantages of Laser Cutting?
Laser cutting is still used today because of its outstanding engineering advantages like superior precision, flexible material selection and design, and cost-effective production.
Precision and Consistency
Today, laser cutting achieves positioning accuracy of ±0.01 mm and repeatability of ±0.005 mm. This is particularly critical for assemblies and weldments, significantly reducing subsequent fitting and rework costs.
Material & Design Flexibility
Laser cutting is virtually unaffected by material hardness, enabling complex contours, internal holes, and sharp-angle structures. Meanwhile, as a non-contact process, it can minimize part deformation. It means that fewer compromises to accommodate manufacturing constraints, which is the good news for designers.
Low-Volume Production
Laser cutting is a better choice for small-batch and multi-variety production. Laser cutting requires no molds. It needs shorter time to finish manufacturing because the digital parameters can be repeated. According to empirical data, the overall cost of laser cutting is 40%-60% lower than stamping processes when the production batches fall below 500 pieces.
Limitations of Laser Cutting
Though laser cutting is still commonly used in many industries, it has some limitations that can’t be overlook. We have listed three key limitations including heat-affected zone, thickness of plates, and highly reflective materials below. Read carefully to know why you should pay attention to them.
Heat-Affected Zone
Heat-affected zone remains an objective factor. It may impact material fatigue life, particularly affecting high-strength steel. It requires control through process optimization or subsequent heat treatment.
Thickness of Plates
Thicker plates result in slower cutting speeds, increased difficulty in controlling cut perpendicularity, and heightened slag adhesion risks. Not all suppliers possess the capability to stably process plates exceeding 30 mm thickness.
Highly Reflective Materials
Copper, brass, and pure aluminum are highly reflective materials. They demand higher equipment and process specifications for laser cutting. In general, they need green or blue lasers or specialized anti-reflective solutions.
Common Materials Used for Laser Cutting
For engineering purpose, metal materials are often manufactured to precision mechanical parts by laser cutting. In this part, you can know what metal materials are widely selected and why they are chosen.
Carbon Steel
The thickness of carbon steel materials typically ranges from 0.5 to 20 mm. Due to its ease of cutting, smooth cut edges, and low cost, it is frequently used for laser cutting. Typical applications include mechanical structural components, enclosures and cabinets, metal frames, and stair railings.
Paslanmaz Çelik
The thickness range of stainless steel typically spans from 0.5 to 15 mm. Characterized by corrosion resistance and high surface finish, it is a commonly used material for laser cutting. However, stainless steel exhibits low reflectivity, poor thermal conductivity, and a tendency to form slag. Its typical applications include kitchen equipment, medical devices, architectural decoration, and components for the food industry.
Aluminum Alloy
Aluminum alloy is also one of the commonly used materials for laser cutting, characterized by its lightweight properties and high reflectivity. It has numerous typical applications such as electronic product casings, aerospace components, lightweight structures, and signage.
Titanium alloys
Titanium alloys, as raw materials for laser cutting, are typically used in industries with stringent requirements for components, such as aerospace and medical devices, owing to their high strength, lightweight properties, and corrosion resistance.
Conclusion
Laser cutting has evolved into a highly versatile and precise manufacturing technology. It has various types for different purpose and requirements. For applications, lase cutting is usually used to process metal materials such as carbon steel, stainless steel, aluminum alloys, and titanium alloys, etc.
Frequently Asked Question:
1. Can you cut acrylic with a laser cutter?
Yes. Laser cutting is one of the preferred methods for processing acrylic. It achieves high precision, smooth edges, high efficiency, and the ability to cut intricate designs.
2. Can you laser cut polycarbonate?
Yes, but it’s extremely challenging and requires strict control and precise settings. Laser cutting polycarbonate (PC, commonly known as “bulletproof glass”) is considered one of the most difficult common plastics to cut.
3. Can you laser cut carbon fiber?
Yes, but this is a specialized process involving high risk, high difficulty, and requiring extreme protective measures. In actual industrial production, it is typically the last resort rather than the standard method. Generally, we do not recommend processing carbon fiber by using laser cutting.