What Are The Common Types Of Laser?

Laser technology is no longer just a futuristic concept—it’s deeply embedded in industries across Australia, transforming how we approach manufacturing, design, and production. From metal fabrication workshops to the medical sector, laser cutting has become an indispensable tool for precision and efficiency.

As someone who’s worked in various Australian manufacturing sectors, I’ve seen firsthand how laser cutting not only speeds up production but also reduces waste, increases precision, and enhances design capabilities. Whether you’re creating intricate jewellery or building parts for the automotive industry, laser cutting technology is revolutionising the way we work with materials.

In this article, we’ll delve into how laser cutting works, the different types of lasers available, and how each type benefits various industries, backed by real-world examples and key applications.

How Laser Cutting Works: Breaking Down the Process

Laser cutting is a method that uses a focused laser beam to cut or engrave materials with high precision. The process is controlled by advanced CNC (Computer Numerical Control) systems, which means that every cut is programmed for accuracy and repeatability.

What Happens During Laser Cutting?

To get a clearer picture of how laser cutting works, let’s break it down into simple steps:

1. CAD Design Conversion: The design to be cut is first created using CAD (Computer-Aided Design) software, which is then converted into a machine-compatible format.
   
2. Laser Beam Focusing: The laser beam is generated and then directed by mirrors and lenses to focus on a small spot on the material. The intense energy from the laser melts, burns, or vaporises the material.
   
3. Assist Gas: An assist gas, like nitrogen or oxygen, blows away the molten material, ensuring a smooth cut and reducing the risk of oxidation on metals.
   
4. CNC Control: The movement of the laser head is controlled by a CNC system that follows the programmed path, ensuring the cut is made with precision and efficiency.
   

Key Benefits of Laser Cutting

• High Precision: Laser cutting allows for extremely accurate cuts, making it ideal for intricate designs.
  
• Minimal Material Waste: The precision of laser cutting ensures minimal wastage, making it an efficient process for large-scale manufacturing.
  
• Flexibility with Materials: Laser cutters can handle a variety of materials, from metals to plastics and even wood, making them versatile tools in any industry.

Types of Lasers for Cutting: Which One Should You Choose?

When selecting a laser cutter, it’s important to consider the type of laser that best suits your material, thickness, and project requirements. Over my years of experience in the industry, I’ve worked with several laser types, each with its unique strengths.

Table: Comparison of Common Laser Types

Laser Type	Best For	Advantages	Limitations
CO2 Lasers	Non-metals like wood, acrylic, textiles	Versatile, lower initial cost, smooth edges	Less effective for thick metals, requires more maintenance, high operating costs
Fiber Lasers	Metals like stainless steel, aluminium	Exceptional precision, fast, energy-efficient, low maintenance	High initial cost, limitations with very thick materials (over 20mm)
Nd:YAG/Nd:YVO Lasers	Thin metals, ceramics, plastics	High beam quality, versatile, relatively low maintenance	Higher initial cost, limited lifespan, lower energy efficiency
Direct Diode Lasers	Thin metals, plastics, composites	Excellent energy efficiency, long lifespan, low maintenance	Lower cutting speeds for thicker materials, variable beam quality

CO2 Lasers: The Versatile All-Rounder

CO2 lasers have long been a popular choice in the Australian fabrication sector, especially for non-metallic materials like wood, acrylic, textiles, and even glass. I’ve worked with local fabricators who use CO2 lasers for creating custom signs, engravings, and decorative pieces. Their ability to produce clean cuts without significant material distortion makes them perfect for these applications.

• Advantages:
  
  • Great for a wide range of non-metals.
    
  • Low initial investment.
    
  • Produces smooth, clean cuts with minimal debris.
    
• Limitations:
  
  • Not effective for cutting thick metals.
    
  • More maintenance required due to optical components.
    
  • Higher operating costs, particularly for cooling and power consumption.
    

Despite these limitations, CO2 lasers are often the go-to option for small businesses due to their cost-effectiveness and versatility. However, when cutting thicker metals, other types of lasers like fibre lasers are more efficient.

Fibre Lasers: Precision for Metals

Fibre lasers are the go-to choice when you need precision and speed for cutting metals. I’ve seen these lasers in action at Australian workshops cutting through stainless steel, aluminium, and even copper. The beam quality and cutting speed of fibre lasers are unparalleled, making them ideal for high-precision industries like aerospace and automotive manufacturing.

• Advantages:
  
  • Exceptional precision and beam quality.
    
  • Faster cutting speeds, especially for thin metals.
    
  • More energy-efficient than CO2 lasers (2-3 times more).
    
  • Low maintenance with a long lifespan.
    
• Limitations:
  
  • Higher initial investment.
    
  • Less effective for cutting materials thicker than 20mm, though high-powered fibre lasers are available for thicker materials.
    

Fiber lasers are increasingly becoming the preferred choice in industries where speed and accuracy are paramount, such as the automotive and aerospace sectors. Their ability to cut through reflective materials like copper without issues makes them incredibly useful in today’s high-tech world.

Nd:YAG/Nd:YVO Lasers: Crystal Power

Nd:YAG (neodymium-doped yttrium aluminium garnet) lasers are crystal-based lasers that are widely used in industries requiring high cutting power. They’re a bit of a niche option, often used for tasks like engraving and cutting ceramics, plastics, and thin metals. I’ve seen these lasers used in the medical field for precise cutting of small medical components like surgical tools.

• Advantages:
  
  • High-quality beam with low divergence.
    
  • Excellent cutting power for thin metals.
    
  • Versatile—works with both metals and select non-metals.
    
• Limitations:
  
  • Higher initial cost.
    
  • Limited lifespan (around 8,000-15,000 hours).
    
  • Expensive pump diodes increase operating costs.
    

These lasers offer a good balance between quality and power but may not be the best fit for thick materials, which is why industries that deal with thin metals or high-precision requirements tend to favour them.

Direct Diode Lasers: Compact and Efficient

Direct diode lasers (DDL) are more energy-efficient than fibre lasers and are often used for high-speed cutting and welding of thin metal sheets. While I’ve seen their application in various industries like electronics and automotive, direct diode lasers excel in fast-paced production environments. Their compact size makes them ideal for situations where space is limited, and their low maintenance requirements ensure longer operational hours.

• Advantages:
  
  • Excellent energy efficiency.
    
  • Longer lifespan with low maintenance.
    
  • Compact size, perfect for mobile applications.
    
• Limitations:
  
  • Lower cutting speeds for thicker materials compared to fibre or CO2 lasers.
    
  • Variable beam quality for high-precision tasks.
    

Direct diode lasers are a solid choice for industries that prioritise speed and energy efficiency, especially in mobile or space-constrained environments.

Laser Marking Technologies: Adding Identity and Style

While laser cutting is the go-to method for slicing through materials, laser marking is an equally essential technology for adding permanent markings, logos, and text to surfaces. Laser marking technologies like engraving, etching, annealing, and ablation have been embraced by industries like medical device manufacturing, automotive, and electronics.

Laser Engraving vs. Laser Etching: What’s the Difference?

• Laser Engraving: This process removes material to create a deep, permanent mark. I’ve seen this used in jewellery production, where intricate designs are permanently engraved on precious metals.
  
• Laser Etching: It creates a raised mark by melting the surface of the material. I’ve worked on laser etching applications where precision was required for coated metals, giving them a high-contrast, durable design.
  
• Laser Annealing: This changes the colour of metals through heat but doesn’t disturb the surface structure. It’s great for creating coloured markings on stainless steel without damaging the surface integrity.
  

Specialised UV Laser Marking for Sensitive Materials

UV lasers are used for marking materials that are sensitive to heat, such as plastics and electronics. In the semiconductor industry, I’ve seen these lasers create fine, high-contrast marks without causing thermal damage, which is crucial when working with heat-sensitive components.

Choosing the Right Laser Cutter for Your Needs

Choosing the right laser cutter for your business isn’t a decision to be taken lightly. Whether you’re cutting metals in an automotive factory or creating intricate jewellery designs, selecting the right equipment is key to success.

Key Considerations When Choosing a Laser Cutter

Material Compatibility and Thickness:

• Make sure the laser type matches the material you’re working with. For example, fibre lasers are perfect for cutting metals, while CO2 lasers work better with non-metals like wood and plastics.
  

Precision and Beam Quality:

• If your industry requires tight tolerances (e.g., aerospace or medical device manufacturing), you’ll need a laser cutter that offers superior precision. Fibre lasers tend to offer the best beam quality.
  

Speed and Throughput:

• For high-volume production environments, fibre lasers are your best bet due to their speed and efficiency. They can cut through materials at high speeds without compromising on quality.
  

Cost Considerations:

• Factor in both the initial investment and the ongoing operating costs. Fibre lasers may have a higher initial cost but will save you money in the long run due to their efficiency and low maintenance.
  

Maintenance and Reliability:

• Ensure the laser cutter you select can handle your production needs without requiring constant repairs. Fibre lasers are known for their long lifespan and low maintenance.
  

Applications and Benefits of Laser Cutting

Laser cutting is used in various industries across Australia, delivering precision, speed, and cost savings. Here’s a look at some of the key applications:

• Manufacturing: Laser cutting is crucial for producing mechanical parts, custom components, and housings in metal fabrication.
  
• Aerospace & Automotive: These sectors rely on laser cutting to meet strict tolerances and create lightweight, durable components.
  
• Electronics & Semiconductor: Laser cutting is used to cut intricate components and micro-parts in the electronics industry.
  
• Medical Devices: The medical sector benefits from the precision of laser cutting to create implants, surgical tools, and catheters.
  
• Art & Design: Laser cutting allows for intricate designs and engravings in art, jewellery, and sculptures.
  
• Signage: Custom signage from various materials, including wood, metal, and acrylic, is commonly made using laser cutting.

Laser cutting technology has revolutionised the way industries approach material cutting and marking, offering unmatched precision, speed, and cost-effectiveness. Whether it’s for large-scale manufacturing or creating intricate designs, laser cutting continues to drive innovation across multiple industries in Australia and beyond.

With ongoing advancements in laser technology, the future of manufacturing looks brighter than ever. By understanding the types of lasers available and choosing the right equipment for your