Unlocking the Full Potential of Precision Laser Cutting

Precision laser cutting technology has come a long way in the last decade, and it’s becoming easier for more people to use.

In 2022, the global market for laser cutting machines was worth $6,832.8 billion, and it’s expected to reach $10,668.36 billion by 2030, according to Allied Market Research. This growth is happening because manufacturers from various industries are turning to precision laser cutters to make their production processes faster, more efficient, higher in quality, more capable, and more reliable.

So, what exactly is precision laser cutting? It’s a process where a powerful and precise laser cuts through materials with a very narrow cut and tight measurements. Compared to old-fashioned cutting methods that use physical blades or abrasive jets, precision laser cutters can work all day with very little supervision and produce complex parts with incredible accuracy.

At Engineered Mechanical Systems, we’re experts in precision laser cutting services. We have a fleet of top-notch laser machines that can handle both big and small jobs, cutting intricate parts to your exact specifications at record speed.

In this article, we’ll talk about five ways that using precision laser cutting technology can help manufacturers improve product quality, streamline workflows, save money, and meet customer demands.

1. Speed and Efficiency Gains

One of the biggest advantages of precision laser cutting is the sheer speed at which parts can be produced compared to conventional fabrication methods. Lasers can operate continuously with minimal downtime and cut through material faster than physical cutting tools that require frequent changes.

For example, laser cutting speeds for 1/4" mild steel plate are typically around 40 IPS (inches per second) versus 10-15 IPS for processes like CNC machining or punching. For thinner gauge sheet metal, laser cutting speeds can exceed 100 IPS.

Beyond raw cutting speed, precision laser cutting also consolidates steps in the manufacturing sequence. Parts that may have required separate operations like drilling, milling, and finishing can often be completed in one streamlined job.

As an illustration, switching to laser cutting enabled one contract manufacturer to reduce production time for a stainless steel orthopedic implant from 12 minutes to just 2 minutes per part — boosting output from 300 units per day to over 2,000 units per day with the same staffing level, an efficiency gain of over 500%.

2. Enhanced Quality Control

Precision laser cutting delivers more consistent, high-quality results, with far fewer errors, defects, and much less scrap material than other fabrication methods. Lasers can hold incredibly tight tolerances, commonly reaching ±0.005" for high precision systems, and produce clean, smooth edge cuts without burrs or deformities that usually require secondary finishing.

Many medical device manufacturers rely on laser cutting for nitinol stents and small stainless steel biopsy forceps where accuracy and surface finish are paramount. Aerospace companies also use precision laser cutting to produce intricate aluminum and titanium components that must adhere to strict certification rules.

3. Design Freedom

Precision laser cutting grants manufacturers far more design freedom compared to conventional fabrication techniques. Lasers place almost no restrictions on part geometries — any 2D profile can be cut quickly and accurately, allowing for innovations like intricate medical implants, miniature electronics enclosures, and lightweight aerospace structures.

Designers no longer have to avoid undercuts, small radii, thin walls, and other features that are unfriendly to tools like punch dies. Laser cutting also enables miniaturization and density improvements through its ability to yield tiny, closely spaced features — cutting thin walls, small holes, and sub-millimeter gaps for electrical or fluidic interconnectivity.

4. Material and Process Consolidation

Precision laser cutting also enables major process consolidation because lasers can cut such a wide range of materials — everything from stainless steel and aluminum to plastics, wood, textiles, and acrylics can be cut with the same laser system.

Switching between materials requires no changeover or retooling — the laser power and settings are simply adjusted. As an example, a medical device company manufacturing components from plastics, ceramics, and titanium consolidated 5 different machining and etching processes down to a single laser cutting system, decreasing their per-part processing time from 52 minutes down to just 12 minutes — 4.3x faster.

5. Consistent and Reliable Results

The automated precision of laser cutting ensures consistent, reliable results that match design intent every time. Precision laser cutters are highly repeatable thanks to CNC coordination and minimal tool wear, resulting in every part coming out identical with no deviations or surprises requiring inspection and rework.

For example, an automotive OEM switched their airbag component fabrication from steel rule stamping presses to laser cutting. The dimensional consistency improved from +/- 0.5mm down to +/- 0.05mm, completely eliminating faulty activations.

Realize the Full Potential of Your Manufacturing

Implementing precision laser cutting technology is a strategic investment that enables manufacturers to achieve new levels of speed, efficiency, quality, capabilities, and reliability. Upgrading to laser cutting offers:

• Faster turnaround times — up to 5x or more
• Reduced errors, defects, and material waste
• Ability to produce highly complex part geometries
• Consolidated workflow for all material types
• Consistent, reliable results over long production runs

At Engineered Mechanical Systems, we are ready to partner with you on implementing precision laser cutting. Our team of experts can conduct production trials and sample part runs to demonstrate the technology’s advantages for your specific application. Contact us today to discuss how precision laser cutting can help you gain a competitive edge.