7 Crucial Aspects to Consider Before Purchasing a Fiber Laser Cutter

Choosing a fiber laser machine can become a complex task if you don't know what parameters to look at. It's a significant, long-term investment, and you want to get it right. If you're planning on purchasing a fiber laser machine in the near future, these are the seven key aspects you should take into consideration:

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1. Laser Power

2. Motion Dynamics

3. Cutting Table Size

4. Automation Capabilities

5. Software and Usability

6. Accuracy and Overall Quality

7. Service and Support

 

Let’s look at each one in detail to help you make an informed choice:

 

1. Laser Power

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Power levels have seen an exponential increase lately, escalating from 4kW to up to 40kW in today's most powerful machines, and they're likely to get higher. In fact, fiber laser R&D systems can go beyond 100kW. So, if higher powers are possible, why are they still not available? The key lies in the beam delivery system. Only a cutting head with superb optical purity and minimal contamination will be able to handle 15, 20, or 30kW without compromising accuracy or reliability.

 

Now, how much power do you really need? That depends on three things:

 

• The thickness of the material you handle

• Your production volume

• The rate at which your business is growing

 

The Thickness of the Material You Handle

 

Material thickness is a good indicator of how much power you will need, although it's always important to consider your production volume and growth rate. Powers above 15kW are not necessary for material 0.5mm or thinner. In fact, if you did have a 15 or 20kW machine, you would probably turn it down to 6kW for it to cut at top speed.

 

However, this doesn't mean that powers above 10kW are reserved for thick plates. A 15kW machine combined with 3 to 6G acceleration can be a great tool on sheets as thin as 2.9mm. If you deal with extreme volumes, high wattage and acceleration allow for ultra-fast cutting and significantly affect throughput. If you handle sheets anywhere from 5mm to 30mm and, depending on the material, even thicker, you should consider a 20 to 30kW machine.

 

This might seem like an excessive amount of power, but if you take into account that production per hour drastically increases while cost per part drops, it's not. That is, of course, provided that the machine dynamics meet the challenge. For a clearer visualization of how power can exponentially increase profits on medium to thick sheet cutting, check our Tower of Power practical example.

 

 

Your Production Volume

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If you deal with thin sheets and make custom parts at medium to low production volumes, don't worry about powers above 6-10kW. You won’t need them. However, if you're in the high-volume business, you should consider wattages above 10kW even for materials around 11 gauge (approximately 3.18mm).

 

Also, you might be working with thin sheets today but planning on expanding your line of business in the future. So take into account your mid to long-term business goals. If they include working with thicker sheets and plates or increasing production volume, you might regret having bought a 6kW machine when a 15kW would now be helping you fulfill your orders faster.

 

 

The Rate at Which Your Business is Growing

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Your business growth rate is also an aspect you want to study when choosing the power of your next fiber laser cutter. Maybe today you're doing fine with a 6kW machine because you don't receive enough orders to keep a 15 or 20kW machine busy full-time. You might think the investment is not worthwhile. And you would be correct if the projections for your business are to remain at similar production volumes.

 

However, if you're growing at a fast rate, you'll need more production capacity sooner rather than later. Investing in a 10kW, 12kW, 15kW, or 20kW machine may result in low occupancy initially, but this gives you room for growth later on or even for providing cutting services for external parties. We already know that more powerful machines can cut much faster, resulting in more parts per hour and a lower cost per part. So, if your business is growing rapidly, higher power will ensure you have enough capacity to handle a rising number of orders.

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2. Motion Dynamics

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Before we delve into the details of dynamics, it's crucial to understand that power and speed work hand in hand. If you're impressed by ultra-high powers and purchase a high-wattage machine with poor motion dynamics, it's likely that your productivity won't see much of an increase.

 

We can all agree that the faster you cut, the better, so looking at speed and acceleration parameters is essential. As a short recap on mechanics, speed is the distance covered in a unit of time, while acceleration is the rate of change of that speed.

 

a) Speed

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First, you should consider positioning speed since it will apply to all your cutting jobs, no matter the thickness. Machines with high positioning speeds (above 300m/min) tend to have high cutting speeds (above 100m/min). For example, delivers a maximum positioning speed of 340m/min and a maximum cutting speed of 150 m/min for a 1530 model (1.5m x 3m cutting table). But speed alone won't do the job. That's when acceleration kicks in.

 

b) Acceleration

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We measure acceleration in Gs, where G is equivalent to the acceleration of gravity (9.81 m/sec²). If we double the acceleration, we're technically reducing the time it takes to reach a programmed speed to half. The rate at which the machine can decelerate into corners or arcs and then accelerate out of them has a higher impact on cycle time than both power and speed. In other words, if a machine can't accelerate at a fast enough rate, all the power in the world will be of no use, so this is a parameter you don't want to overlook.

 

For a speedy performance, consider machines between 3G and 6G and keep in mind that the higher the power, the more critical the role of acceleration in cycle time. When the rest of the parameters are roughly the same, the higher G machine will always produce parts faster, whether the material is thick or thin.

 

 

3. Cutting Table Size

 

This might seem like an obvious point, but it is critical when choosing the right laser cutter. Consider the average sheet size you process the most and make sure the machine will be able to accommodate it.

 

Regarding table size, you should also take into account any future growth plans. Do you see yourself cutting that sheet size for the next 10 years? Do you plan to expand your range and size of products? If the latter is the case, make sure to choose a table size that will allow for this expansion.

 

Moreover, you may cut unusually large sheets, in which case you need to look for a manufacturer that offers the appropriate cutting table or can make custom-sized ones.

 

To get an idea of the available sizes, download Eagle’s machine specifications and compare length, width, height, and weight parameters depending on each model.

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4. Automation Capabilities

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We’ve mentioned power and speed as two aspects that go hand in hand. The third element that completes a seamless and efficient production cycle is automation.

 

Fiber lasers work fast, so the material needs to be loaded and unloaded quickly to keep pace with the production speed. Pallet changers originally manufactured for CO2 lasers (where the cutting process was slower) could take between 30 seconds and 1 minute to exchange metal sheets. Today's fastest pallet changers do the job in 9 seconds!

 

Automating material handling, exchange, and storage systems is essential to keep the production flow swift, uninterrupted, and even running shifts unsupervised at night or during weekends. So, you want to look at a fast pallet exchange, automated loading and unloading systems, as well as storage towers. These three elements work in sync to feed the machine with fresh sheets while unloading and storing cut parts for smooth production with the highest efficiency.

 

Nowadays, it’s not a matter of whether to choose automation or not. Most companies know for a fact that it is a must when working with fast-cutting machines. The question then becomes: Which automation system do I choose?

 

While there are several great quality manufacturers out there, one of Eagle’s key differentiators is that we fabricate our own automated material handling and storage systems. Aside from the fact that we use rigid profiles that are twice as heavy as others in the market, the main advantage of acquiring a machine and automation from a sole manufacturer is that there is no room for error. The CraneMaster and eTower systems are designed to perfectly fit the capabilities of the cutting machine they’ll be working with; what the laser can cut, the automation can handle.

 

Another aspect to look at when choosing automation systems is flexible configurations. Modular setups make the best choices because they can adapt to your hall, making the most of floor space while providing maximum storage capacity.

 

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5. Software and Usability

 

Software

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A good laser cutter can always perform better with intuitive software that enhances efficiency and speeds up workflow. Some of the questions you should be asking any potential manufacturer you're considering purchasing your machine from are:

 

• Do you offer proprietary software?

• Is it intuitive and easy to use for new and experienced operators?

• Will I receive software upgrades if there are any in the future?

• How does your software apply to my particular needs and how can it enhance my cutting?

• Will your software help me save energy and reduce waste?

 

 

Today, there are all kinds of technologies available that can significantly improve your metal cutting processes, from delivering better edge quality and reduced burrs to gas mixing and lowering gas consumption, to increasing material thickness with the same power, and more.

 

On the safety aspect, we recommend you ask about remote process monitoring and fault detection software, which will give you full control over operations and help minimize machine downtime. You are sure to find something worth the purchase depending on your specific requirements.

 

Usability

 

Tightly linked to software is usability. In other words, how user-friendly is the machine? Keep in mind that the easier it is to grasp the HMI and program controls, the faster an operator will get the hang of it, and the faster you can start cutting and making full use of your machine. In today’s digitalized world, a machine interface should aim to be as easy to use as a smartphone. Even more so when labor shortages are a prevalent issue, ease of use and a modern interface are key to attracting young talents.

 

However, usability is not restricted to the HMI but also includes machine ergonomics and accessibility. It may sound trivial, but once the machine is running, you will notice the importance of operator comfort and its impact on productivity.

 

Look for a human-centric machine with large multi-touch screen displays, a clear line of sight to the cutting table, easy access to cut parts, and reliable safety features.

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6. Accuracy and Overall Quality

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A reliable machine will deliver precise and high-quality cuts. For this to be the case, you have to invariably look at two aspects, the second being the result of the first:

 

• Machine construction

• Maintenance requirements

 

If a machine offers very high wattages but is poorly constructed, it will not perform accurately, even less so at ultra-high speeds. On the other hand, constant maintenance requirements result in frequent downtime, and nobody wants to see their big investment idly sitting without making a profit.

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Machine Construction

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First and foremost, you want to look at the accuracy and reliability of the cutting head. This is arguably a laser cutter’s most important component, especially in high-wattage machines, because it needs to withstand and control immense power while remaining stable and delivering a precisely focused beam at all times.

 

Eagle’s eVa cutting head has revolutionized the industry. Its patented construction with no moving elements inside the head structure and the greatest distance from nozzle to cover slide on the market make it five times less prone to contamination. The large distance to the slide also results in ten times less frequent glass replacement. The eVa needs minimum maintenance, most of which can be carried out by your own personnel.

 

Other aspects worth paying attention to are component material and lifetime. Are the machine components top quality, and will they last for its entire life cycle? You want to look at machine body construction and pay attention to vibration damping and temperature coefficients. Eagle machine bodies are made of polymer concrete, a composite material with 100 times higher vibration damping and ten times lower temperature coefficient than steel.

 

Reliable dynamic motion will depend on components like the traverse, the motors, and the encoders. A lightweight but sturdy traverse will move a lot faster. Eagle’s top-of-the-line iNspire laser cutters feature a carbon fiber traverse, the same super strong and light material used in Formula 1 cars and high-performance sports equipment for the speediest motion. Additionally, Eagle’s Ideal Machine Concept design positions the traverse between the machine’s left and right body walls for the highest stability.

 

Look for linear motors on all axes, which will guarantee frictionless movement and top accuracy even at the highest acceleration parameters. Absolute linear encoders will give you 100% control over dynamic motion and, like linear motors, they’re contactless and wear-free, so they need no maintenance and ensure peak performance for your machine’s entire life cycle.

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Maintenance Requirements

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The most efficient construction will always result in the least maintenance. In fiber laser cutting machines, less is more when it comes to components. The math is simple: what is not there cannot break down. The smartest design will boil it down to the essential elements, resulting in reduced maintenance requirements.

 

That being said, make sure to ask about the maintenance needs of the elements that are there. Are they made in-house? If not, who are the providers? Are they reliable, renowned brands? Where are they made?

 

At Eagle, we make 80% of our components in-house in the EU, including the cutting head and linear motors. The rest come from the highest quality providers such as IPG Photonics, Renishaw, Beckhoff, and Messer.

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7. Service and Support

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Last but not least, always make sure the fiber laser manufacturer has a strong and trustworthy support network. Service should start from day one, with installation and training programs that will leave your machine ready to start cutting and your operators knowing how to properly use it.

 

You want to ask every detail about what the procedure will be in case your machine needs servicing and make sure there will be technicians ready and able to provide you with prompt assistance.

 

Does the manufacturer have a strong and reliable service network in your country? Do they offer training programs? What kind of warranty packages do they have? How long will spare parts take to reach your facilities? Do they offer remote online assistance for minor issues? These are all questions you can’t spare.

 

At Eagle, customer satisfaction is our top priority, which is why, aside from an experienced service team and the best partners worldwide, we’ve designed a specialized software called MyESP (Eagle Service Platform).

 

MyESP allows operators to send service requests directly from the machine, describing the issues and even including videos and photos to help our team better understand them. Once submitted, these requests go directly to our Service Department, where immediate steps are taken to fix the problem and have your machines running smoothly in the shortest possible time.

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To Summarize 

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1. Laser Power: The thicker the material you cut, the more important this parameter becomes. Consider a power that will be able to handle your current workload and material thickness, but don’t forget to plan for future growth and portfolio expansion.

2. Motion Dynamics: They’re more important than power when dealing with thin sheets. Remember to look at acceleration parameters and preferably choose from 3G upwards. When all other parameters are the same, it’s the Gs that will make the difference.

3. Cutting Table Size: Consider the sheet size you work with the most, but don’t rule out growth possibilities. If you work with oversized material, be sure to ask if the manufacturer provides table sizes to accommodate it.

4. Automation Capabilities: For mid-to-high volume, some level of automation will be required. Be sure to ask about the differences in configurations and setups to choose what makes the most of your available floor space.

5. Software and Usability: Inquire about the HMI and look for the highest user-friendliness in every aspect. Ask about software that may help you enhance your specific cutting needs, and make sure the machine is comfortable, safe, and accessible for operators.

6. Accuracy and Overall Quality: Ask about machine component design and origin to ensure you choose reliable equipment. You want the highest quality with minimum breakdowns and maintenance requirements.

7. Service and Support: You can never ask enough about the support network in your area. You want a manufacturer that will provide training, prompt assistance, rapid spare part delivery, and comprehensive warranty plans.

 

With these seven points as a guideline, you’re ready to choose the right fiber laser cutter and take your productivity to a whole new level.