The versatility and accuracy of laser cutting machines make them ideal for cutting two-dimensional forms and designs from a wide range of materials. While most people associate laser cutting with flat surfaces, recent innovations in the field have made it possible to use laser-cut components to build three-dimensional structures and things.
Laser engraving, etching, and the use of pre-cut components are some of the fabrication techniques that can be used with laser cutting machines to create complex three-dimensional structures, even if the machines themselves only work in two dimensions.
One method makes use of laser-cut parts that may be assembled into three-dimensional forms by locking or fitting them together. It is possible to build intricate three-dimensional structures out of these parts by carefully carving patterns, slots, or joints into numerous flat pieces.
In addition, utilising kerf bending allows for the fabrication of three-dimensional shapes by taking advantage of the laser's cutting width, or kerf, to make folds or bends in materials such as wood or acrylics. When put together, structures made with this technique give the impression of depth and dimension.
Furthermore, complex three-dimensional things are now within reach, thanks to developments in additive manufacturing, especially laser cutting in conjunction with 3D printing technology. By selectively cutting or etching materials before or after the additive manufacturing process, hybrid systems that combine laser cutting with 3D printing can produce layered structures, which aid in the construction of complicated three-dimensional items.
Although laser cutting machines are mainly used for two-dimensional operations, new approaches and supplementary manufacturing technologies have made it possible to include them into processes that manufacture intricate and precise three-dimensional structures and objects.
Table of Contents
What Is 3D Laser Cutter?
The term "3D printing" is now parlance, and most people understand what it can do for both personal and commercial use. However, the fact that there are equipment that can enhance this technology is less well recognised. Here, we'll focus on laser cutters.
While 3D printers and laser cutters are functionally opposed, they share some similarities in the building industry. A three-dimensional object can be created with a 3D printer by using raw materials (such as filament, pellets, resin, etc.) that have a different shape than the finished product.
Laser cutters, on the other hand, can only work in two dimensions and require larger and identically shaped raw materials (such as wood or steel) than what will eventually be assembled. Expert laser cutters have the advantage of being able to quickly and easily cut through an endless variety of materials, particularly metals.
Utilising a rail system to guide a moving head, the laser cutter is able to cut through a variety of materials, including metal, wood, and leather, with a thickness of up to 6 mm. Because they provide consistently small radii for holes and curves, as well as extremely narrow slot widths, laser cutters find extensive usage in industry.
Complex flat items, which would normally be significantly more costly with another production process, are typically what it offers value for. Plus, these machines can achieve a flawless, burr-free surface quality while operating at extremely high rates, all without sacrificing precision.
Two distinct varieties of laser cutters exist, Mr. Beam II and CO2 lasers, distinguished by the type of laser they employ. In a carbon dioxide laser, the laser beam is produced by two diode bars that are housed within a glass tube along with other concentrated chemical components.
This laser type has a narrow beam and a short operational life (1000–15,000 hours), which are its main drawbacks. The operation of a laser diode is comparable to that of an LED, except that the laser beam is intensely concentrated and the power is extremely high. They outperform CO2 lasers in terms of accuracy and have an extremely long service life.
Professionals in fields other than manufacturing can make use of laser cutters like Mr. Beam II, which can cut and etch a vast array of materials. Here we have a cutter that includes a 5W class 1 laser head, a fume extraction and filtering system, a safety cover, and a metal housing. The addition of a lid camera and its WLAN connectivity will make it much easier to pinpoint exactly where on a design you wish to make cuts or burns.
How It Compares to Laser Cutting
Layers of material, such as plastic or metal, are added to a product using the 3D printing process. It was in Japan in the early 1980s that its earliest known versions were documented. A UV-polymerized photosensitive resin was the basis of Hideo Kodama's rapid prototyping technique. A plethora of 3D printing technologies, including FDM, SLS, DED, and SLM, have evolved throughout the years. Both FDM and DED include layer-by-layer material laydown through a nozzle.
In contrast, selective laser melting (SLM) and layer-by-layer (LWS) fuse powder particles until the item is finished. Contrasted with the subtractive nature of laser cutting, which removes pieces from sheet stock, 3D printing adds new layers to the material. To learn more, check out our 3D printing definition guide.
Differences Between 2D Laser Cutting, 3D Laser Cutting, and 3D Printing
One major advantage of 3D laser cutting over 2D is the ability to forge in a vertical orientation. But many wonder how these two forms of laser cutting stack up against 3D printing. Layer by layer, 3D printers construct materials, and layer by layer, laser cuts remove them.
The total amount of time it takes to complete each project is significantly affected by this. It is common to have to cut and glue the components to the surface of the 3D printed object because these projects tend to be narrower than 3D cut ones.
3D printers create their creations by layering components and fusing powders of the materials of choice. Conversely, solid-state lasers or carbon dioxide (CO2) are used by laser cutters to melt the materials of their workpieces. Making a product costs more because of this basic distinction.
The metal powder used by 3D printers is more costly to procure than the sheet metal required by laser cutters. The versatility of 2D and 3D laser cutters is enhanced by their larger workbeds compared to 3D printers, which allow them to tackle a wider array of tasks.
3D Laser Cutting System’s Operation
Fundamentally, 3D laser cutting is a method of precise manufacturing that makes use of the unique characteristics of a concentrated laser beam to cut materials in three dimensions. A succession of meticulously orchestrated steps determine the outcome of this intricate process:
- Start with a high-power laser generator, usually one that uses carbon dioxide (CO2) or fibre lasers. For each given material, the ideal laser generator will have different cutting characteristics.
- A sequence of focusing optics converges the laser beam into a focused one once it has passed through the optical system. Reliability of the laser generator is highly dependent on these optics.
- Relationship between materials: The material's surface is illuminated by an intense laser beam. The substance is either melted, evaporated, or blasted away as a result of the tremendous heating that occurs when the laser meets the material. Material qualities and laser parameter settings determine the results.
- Oftentimes, computer software systems will employ computer numerical control (CNC) to coordinate the entire process. Software like this can take an item's three-dimensional CAD model and turn it into laser cutting machine compatible instructions.
- Rotation on multiple axes: Operating in three dimensions (X, Y, and Z axes) is a defining property of 3D laser cutting. The laser's remarkable pliability allows it to trace intricate three-dimensional patterns, creating intricate geometries, curves, and forms with unmatched accuracy.
- On-the-fly changes: CNC software keeps an eye on the laser's power, speed, and focus while it cuts, allowing for precise modifications in real time. Regardless of how complicated the work is, this real-time adjustment will produce perfect results every time.
Reasons to Use 3D Laser Cutting
There are a number of benefits and drawbacks to 3D laser cutting, a flexible and precise technique, that are application and necessity dependent. 3D laser cutting has the following primary benefits and drawbacks:
- The exceptional accuracy and precision offered by 3D laser cutting systems make them the go-to for intricate designs. It ensures constant quality by cutting with tolerances within millimetres. Manufacturing aerospace and medical devices are two examples of sectors that greatly benefit from this.
- 3-D laser cutting devices are incredibly versatile, capable of cutting through a wide range of materials. From metals and plastics to ceramics and composites, the possibilities are endless. Its adaptability makes it a good fit for many different fields and uses.
- Efficiency and speed: Compared to more conventional cutting techniques, laser cutting is lightning fast. Rapid part production and enhanced overall production efficiency are both possible with its support.
- Minimal tool wear: Lasers eliminate the need for physical tools that wear out over time, in contrast to more conventional cutting processes. As a result, there is less need for maintenance and the quality remains steady for a longer duration.
- Cutting with a laser results in far less material waste than other processes since the beam can be fine-tuned. Particularly when dealing with pricey materials, this can help keep expenses down.
- The use of a laser cutter eliminates the possibility of material distortion, contamination, or tool wear due to the fact that the cutting tool does not come into direct touch with the material.
- Geometries that are difficult, if not impossible, to cut with conventional methods can be effortlessly created with 3D laser cutting.
- Through the integration of 3D laser cutting equipment with CAD/CAM software, computer-controlled cutting can be achieved, leading to a decrease in labour costs and a reduction in the likelihood of human error.
- Cutting with a laser causes very little heat-affected zone (HAZ), which means that the material is subjected to very little deformation and metallographic changes. The preservation of material qualities makes this especially crucial for materials like metals.
- Never pay for mould: Setup time and expenses are reduced with 3D laser cutting since it does not require costly mould changes for new designs or materials, unlike certain older cutting processes.
Conclusion
Laser cutting machines can cut a lot of different materials into two-dimensional shapes and designs, and they are very exact. New technologies, like laser cutting, etching, and the use of pre-cut parts, have made it possible to use laser-cut parts to build complex three-dimensional structures and things.
Locking or fitting laser-cut parts together makes it possible to put them together in three dimensions to make complex structures. By using the laser's cutting width, or "kerf," to make folds or bends in materials like wood or plastics, kerf bending lets you make three-dimensional shapes.
Laser cutting and 3D printing can be used together in hybrid systems to make stacked structures that help build complicated three-dimensional objects. A laser cutter can cut through an infinite number of materials. They are widely used in the industry because they can work quickly and produce a smooth, burr-free surface. Laser cutters come in two different types: Mr. Beam II and CO2 lasers. Each has its own pros and cons.
3D printing has changed over the years with new technologies like FDM, SLS, DED, and SLM. This method adds layers of material to a product. In FDM and DED, the material is laid down layer by layer through a nozzle. In SLM and LWS, powder bits are fused together until the item is finished.
3D laser cutting is a precise way to make things by cutting them in three dimensions with a focused laser beam. This method is precise and adaptable, so it can be used in many areas, including medical products and aerospace. 3D laser cutting systems are very accurate and precise, and they can cut with errors as small as a millimetre, which ensures consistent quality. This makes them useful in a lot of different areas and situations because they can cut through a lot of different materials.
One of the best things about 3D laser cutting is that it is very accurate and precise, which makes it the best choice for cutting out complicated designs. It is also very fast, which makes it possible to make parts quickly and improves the total efficiency of production. Laser cutting minimises tool wear, cuts down on material waste, and gets rid of the chance of material warping, contamination, or tool wear. It can make complex shapes that are hard to cut the old-fashioned way.
When 3D laser cutting equipment is combined with CAD/CAM software, cutting can be handled by a computer. This cuts down on labour costs and mistakes made by people. It also doesn't create a lot of heat-affected zones (HAZ), which keeps the properties of materials, especially metals.
3D laser cutting doesn't need expensive changes to the model, which cuts down on setup time and costs. Overall, 3D laser cutting is an accurate and adaptable way to do a lot of different things.
Content Summary
- Laser cutting machines are versatile and accurate, making them ideal for two-dimensional forms.
- Recent innovations allow laser-cut components to be used in building three-dimensional structures.
- Fabrication techniques like laser engraving and etching contribute to creating 3D structures.
- Laser-cut parts can be assembled to form intricate 3D structures by carving patterns or joints.
- Kerf bending utilises the laser's cutting width to fold or bend materials, creating 3D shapes.
- Additive manufacturing, combined with laser cutting and 3D printing, produces layered structures.
- Laser cutting machines primarily work in two dimensions but contribute to 3D structure creation.
- The term "3D printing" is well-known, but equipment enhancing this technology, like laser cutters, is less recognised.
- 3D printers and laser cutters share similarities in the building industry despite functional differences.
- Laser cutters, while two-dimensional, can cut through various materials with high precision.
- Laser cutters, like Mr. Beam II and CO2 lasers, are suitable for cutting wood, metal, and leather.
- A 3D laser cutter is used to create three-dimensional objects with a focused laser beam.
- A 3D laser cutter employs a rail system, guiding a moving head to cut through materials.
- CO2 lasers generate a laser beam using diode bars within a glass tube, suitable for various materials.
- 3D laser cutting offers precise manufacturing, utilising concentrated laser beams for three-dimensional cuts.
- A sequence of focusing optics converges the laser beam into a focused state for cutting.
- CNC software coordinates the 3D laser cutting process, converting CAD models into instructions.
- 3D laser cutting operates in three dimensions (X, Y, Z axes) for intricate patterns and forms.
- CNC software allows on-the-fly adjustments to laser power, speed, and focus during cutting.
- 3D laser cutting excels in accuracy, versatility, efficiency, and minimal tool wear.
- Laser cutting is faster than traditional methods, contributing to enhanced production efficiency.
- Laser cutting minimises material waste through fine-tuned beams, which is especially valuable for pricey materials.
- Laser cutting eliminates material distortion, contamination, and tool wear due to no direct contact.
- 3D laser cutting effortlessly creates geometries challenging for conventional methods.
- Integration with CAD/CAM software reduces labour costs and minimises human error in cutting.
- Laser cutting causes minimal heat-affected zone (HAZ), preserving material qualities.
- 3D laser cutting eliminates the need for costly mould changes for new designs or materials.
- Laser cutting machines are used for cutting two-dimensional forms, but recent innovations enable them to contribute to the creation of three-dimensional structures.
- Fabrication techniques such as laser engraving and etching can be employed with laser-cutting machines to build complex three-dimensional structures.
- Laser-cut components can be assembled to form intricate three-dimensional structures by incorporating patterns or joints.
- Kerf bending, a technique that utilises the laser's cutting width, allows for the fabrication of three-dimensional shapes, adding depth and dimension to structures.
- The integration of laser cutting with 3D printing technology enables the production of layered structures, contributing to the construction of intricate three-dimensional items.
- Despite being primarily designed for two-dimensional operations, laser-cutting machines can be included in processes that manufacture precise and complex three-dimensional structures and objects.
- While laser cutters and 3D printers have functional differences, they share similarities in the building industry, with laser cutters contributing to the creation of intricate two-dimensional designs that can be used in three-dimensional structures.
- Laser cutters, such as Mr. Beam II and CO2 lasers, are versatile tools capable of cutting various materials, including wood, metal, and leather, with precision.
- A 3D laser cutter utilises a rail system to guide a moving head and cut through materials, creating three-dimensional objects.
- CO2 lasers, employed in laser cutting, generate laser beams using diode bars within a glass tube, suitable for cutting a wide range of materials.
- 3D laser cutting involves precise manufacturing with a focused laser beam operating in three dimensions (X, Y, Z axes) to create intricate patterns and forms.
- CNC software coordinates the 3D laser cutting process, allowing real-time adjustments to laser power, speed, and focus for perfect results.
- 3D laser cutting offers exceptional accuracy, versatility, efficiency, and minimal tool wear, making it suitable for various applications.
- Laser cutting is faster than traditional methods, contributing to enhanced production efficiency and minimising material waste.
- Laser cutting eliminates material distortion, contamination, and tool wear due to no direct contact with the material being cut.
- 3D laser cutting effortlessly creates geometries challenging for conventional methods, providing unique design possibilities.
- Integration with CAD/CAM software reduces labour costs and minimises human error in the 3D laser cutting process.
- Laser cutting causes minimal heat-affected zone (HAZ), preserving material qualities crucial for materials like metals.
- 3D laser cutting eliminates the need for costly mould changes, reducing setup time and expenses for new designs or materials.
- Laser cutting machines, primarily designed for two-dimensional operations, contribute to the creation of three-dimensional structures through innovative fabrication techniques and additive manufacturing processes.
- Laser cutters, like Mr. Beam II and CO2 lasers, are versatile tools capable of cutting various materials, offering precision and flexibility in design.
- 3D laser cutting involves a precise manufacturing process that uses a focused laser beam in three dimensions to create intricate patterns and forms.
- The integration of laser cutting with 3D printing technology allows for the production of layered structures, expanding the possibilities for creating intricate three-dimensional items.
Frequently Asked Questions
Laser cutting machines can work with materials of varying thicknesses, including those with irregular or non-uniform thickness profiles. However, adjustments to laser settings might be needed to ensure consistent cutting across the material.
After laser cutting, parts may have sharp edges or residual heat. Using appropriate handling tools, wearing gloves, and allowing materials to cool down before handling are important safety measures to avoid injuries.
Laser cutting machines offer high repeatability and accuracy, ensuring consistency in producing parts with precise dimensions. This capability is advantageous for industries requiring standardized components.
Efficient nesting of designs within the material sheet, using optimized cutting paths, and utilizing software features that minimize unused space help reduce material wastage in laser cutting.
Some materials, like certain plastics or wood types, are more prone to burning or charring during laser cutting due to their composition. Careful adjustment of cutting parameters helps mitigate these effects.