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((short description|Technology that uses a laser to cut materials))
((More citations needed|date=May 2023))
[[File:LaserCutter.jpg|thumb|Diagram of a laser cutter|alt=]] 
[[File:Lasercutting-video.ogg|thumb|Laser cutting process on a sheet of steel]]
[[File:Laser cutting CAD and physical part.png|thumb|upright|[[Computer-aided design|CAD]] (top) and stainless steel laser-cut part (bottom)]]
'''Laser cutting''' is a technology that uses a [[laser]] to vaporize materials, resulting in a cut edge. While typically used for industrial manufacturing applications, it is now used by schools, small businesses, architecture, and hobbyists. Laser [[cutting]] works by directing the output of a high-power laser most commonly through optics. The [[laser optics]] and [[CNC]] (computer numerical control) are used to direct the laser beam to the material. A commercial laser for cutting materials uses a motion control system to follow a CNC or [[G-code]] of the pattern to be cut onto the material. The focused laser beam is directed at the material, which then either melts, burns, vaporizes away, or is blown away by a jet of gas,<ref>Oberg, p. 1447.</ref> leaving an edge with a high-quality surface finish.<ref>((Cite journal|last=Thomas|first=Daniel J.|date=2013-02-01|title=The effect of laser cutting parameters on the formability of complex phase steel|url=https://doi.org/10.1007/s00170-012-4087-2|journal=The International Journal of Advanced Manufacturing Technology|language=en|volume=64|issue=9|pages=1297–1311|doi=10.1007/s00170-012-4087-2|s2cid=96472642|issn=1433-3015))</ref>

== History ==
In 1965, the first production laser cutting machine was used to [[drilling|drill]] holes in [[diamond]] [[Die (manufacturing)|dies]]. This machine was made by the [[Western Electric Engineering Research Center]].<ref>((harvnb|Bromberg|1991|p=202))</ref> In 1967, the British pioneered laser-assisted oxygen jet cutting for metals.<ref>The early days of laser cutting, par P. A. Hilton, 11th Nordic Conference in Laser Processing of Materials, Lappeenranta, Finland, August 20–22, 2007, http://www.twi-global.com/technical-knowledge/published-papers/the-early-days-of-laser-cutting-august-2007</ref> In the early 1970s, this technology was put into production to cut titanium for aerospace applications. At the same time, CO<sub>2</sub> lasers were adapted to cut non-metals, such as [[textiles]], because, at the time, CO<sub>2</sub> lasers were not powerful enough to overcome the [[thermal conductivity]] of metals.<ref>CHEO, P. K. "Chapter 2: CO<sub>2</sub> Lasers." UC Berkeley. UC Berkeley, n.d. Web. 14 Jan. 2015.</ref>

== Process ==
[[File:Laser-and-CNC-Control.jpg|thumb|Industrial laser cutting of steel with cutting instructions programmed through the CNC interface]]

The laser beam is generally focused using a high-quality lens on the work zone. The [[M squared|quality of the beam]] has a direct impact on the focused spot size. The narrowest part of the focused beam is generally less than ((convert|0.0125|in)) in diameter. Depending upon the material thickness, [[wikt:kerf|kerf]] widths as small as ((convert|0.004|in)) are possible.<ref>Todd, p. 185.</ref> In order to be able to start cutting from somewhere other than the edge, a pierce is done before every cut. Piercing usually involves a high-power pulsed laser beam which slowly makes a hole in the material, taking around 5–15 seconds for ((convert|0.5|in|mm|adj=mid|-thick)) [[stainless steel]], for example.

The parallel rays of coherent light from the laser source often fall in the range between ((convert|0.06|-|0.08|in)) in diameter. This beam is normally focused and intensified by a lens or a mirror to a very small spot of about ((convert|0.001|in)) to create a very intense laser beam. In order to achieve the smoothest possible finish during contour cutting, the direction of the beam [[polarization (waves)|polarization]] must be rotated as it goes around the periphery of a contoured workpiece. For sheet metal cutting, the focal length is usually ((convert|1.5|-|3|in)).<ref>Todd, p. 188.</ref>

Advantages of laser cutting over [[mechanical cutting]] include easier work holding and reduced contamination of workpiece (since there is no cutting edge which can become contaminated by the material or contaminate the material). Precision may be better since the laser beam does not wear during the process. There is also a reduced chance of warping the material that is being cut, as laser systems have a small [[heat-affected zone]].<ref>((Cite web|title=Laser Cutting - Cutting Processes|url=https://www.twi-global.com/technical-knowledge/job-knowledge/cutting-processes-laser-cutting-052.aspx|access-date=2020-09-14|website=www.twi-global.com|language=en-GB))</ref> Some materials are also very difficult or impossible to cut by more traditional means.

Laser cutting for metals has the advantage over plasma cutting of being more precise<ref name="Laser cutting for metals">((cite web|url=https://vietducmetal.vn/gia-cong-cat-laser-tren-kim-loai-voi-nhieu-uu-diem-vuot-troi/|title=Gia công cắt laser trên kim loại với nhiều ưu điểm vượt trội|trans-title=Laser cutting for metals with many outstanding advantages
|last=Daniel Tuấn|first=Hoàng|language=vi|work=vietducmetal.vn|date=7 October 2020|access-date=4 November 2020|archive-url=https://web.archive.org/web/20201104081701/https://vietducmetal.vn/gia-cong-cat-laser-tren-kim-loai-voi-nhieu-uu-diem-vuot-troi/|archive-date=4 November 2020|url-status=live))</ref> and using less energy when cutting sheet metal; however, most industrial lasers cannot cut through the greater metal thickness that plasma can. Newer laser machines operating at higher power (6000 watts, as contrasted with early laser cutting machines' 1500-watt ratings) are approaching plasma machines in their ability to cut through thick materials, but the capital cost of such machines is much higher than that of plasma cutting machines capable of cutting thick materials like steel plate.<ref>((Cite journal|last1=Happonen|first1=A.|last2=Stepanov|first2=A.|last3=Piili|first3=H.|last4=Salminen|first4=A.|date=2015-01-01|title=Innovation Study for Laser Cutting of Complex Geometries with Paper Materials|journal=Physics Procedia|series=15th Nordic Laser Materials Processing Conference, Nolamp 15|language=en|volume=78|pages=128–137|doi=10.1016/j.phpro.2015.11.025|bibcode=2015PhPro..78..128H|issn=1875-3892|doi-access=free))</ref>

== Types ==

[[File:CNC Laser Cutting Machine.jpg|thumb|4000&nbsp;watt ((CO2)) laser cutter]]

There are three main types of lasers used in laser cutting. The [[CO2 laser|((CO2)) laser]] is suited for cutting, boring, and engraving. The [[neodymium]] (Nd) and neodymium [[yttrium-aluminium-garnet]] ([[Nd:YAG laser|Nd:YAG]]) lasers are identical in style and differ only in the application. Nd is used for boring and where high energy but low repetition are required. The Nd:YAG laser is used where very high power is needed and for boring and engraving. Both ((CO2)) and Nd/Nd:YAG lasers can be used for [[welding]].<ref name="Todd, p. 186">Todd, p. 186.</ref>

((CO2)) lasers are commonly "pumped" by passing a current through the gas mix (DC-excited) or using radio frequency energy (RF-excited). The [[Dielectric heating|RF method]] is newer and has become more popular. Since DC designs require electrodes inside the cavity, they can encounter electrode erosion and plating of electrode material on [[glass]]ware and [[optics]]. Since RF resonators have external electrodes they are not prone to those problems.
((CO2)) lasers are used for the industrial cutting of many materials including titanium, stainless steel, mild steel, aluminium, plastic, wood, engineered wood, wax, fabrics, and paper. YAG lasers are primarily used for cutting and scribing metals and ceramics.<ref>((Cite web|title=What is laser cutting? ((!)) Laser cutting process|url=http://www.cutlasercut.com/getting-started/what-is-laser-cutting-laser-cutting-process|access-date=2020-09-14|website=www.cutlasercut.com))</ref>

In addition to the power source, the type of gas flow can affect performance as well. Common variants of ((CO2)) lasers include fast axial flow, slow axial flow, transverse flow, and slab. In a fast axial flow resonator, the mixture of carbon dioxide, helium, and nitrogen is circulated at high velocity by a turbine or blower. Transverse flow lasers circulate the gas mix at a lower velocity, requiring a simpler blower. Slab or diffusion-cooled resonators have a static gas field that requires no pressurization or glassware, leading to savings on replacement turbines and glassware.

The laser generator and external optics (including the focus lens) require cooling. Depending on system size and configuration, waste heat may be transferred by a coolant or directly to air. Water is a commonly used coolant, usually circulated through a chiller or heat transfer system.

A ''laser microjet'' is a water-jet-guided [[laser]] in which a pulsed laser beam is coupled into a low-pressure water jet. This is used to perform laser cutting functions while using the water jet to guide the laser beam, much like an optical fiber, through total internal reflection. The advantages of this are that the water also removes debris and cools the material. Additional advantages over traditional "dry" laser cutting are high dicing speeds, parallel [[wikt:kerf|kerf]], and omnidirectional cutting.<ref name="SPIE">Perrottet, D et al.,"Heat damage-free Laser-Microjet cutting achieves highest die fracture strength", ''Photon Processing in Microelectronics and Photonics IV'', edited by J. Fieret, et al., Proc. SPIE Vol. 5713 (SPIE, Bellingham, WA, 2005)</ref>

[[Fiber laser]]s are a type of solid-state laser that is rapidly growing within the metal cutting industry. Unlike CO<sub>2</sub>, Fiber technology utilizes a solid gain medium, as opposed to a gas or liquid. The “seed laser” produces the laser beam and is then amplified within a glass fiber. With a wavelength of only 1064 nanometers fiber lasers produce an extremely small spot size (up to 100 times smaller compared to the CO<sub>2</sub>) making it ideal for cutting reflective metal material. This is one of the main advantages of Fiber compared to CO<sub>2</sub>.

Fibre laser cutter benefits include:

* Rapid processing times.
* Reduced energy consumption & bills – due to greater efficiency.
* Greater reliability and performance - no optics to adjust or align and no lamps to replace.
* Minimal maintenance.
* The ability to process highly reflective materials such as copper and brass.
* Higher productivity - lower operational costs offer a greater return on your investment.<ref>((Cite web|last=Fisher|first=Adam|title=Fibre Lasers|url=https://www.ctrlasers.co.uk/fibre-lasers|publisher=CTR Lasers))</ref>

== Methods ==
There are many different methods of cutting using lasers, with different types used to cut different materials. Some of the methods are vaporization, melt and blow, melt blow and burn, thermal stress cracking, scribing, cold cutting, and burning stabilized laser cutting.

===Vaporization cutting===
In vaporization cutting, the focused beam heats the surface of the material to a flashpoint and generates a keyhole. The keyhole leads to a sudden increase in [[Absorption (electromagnetic radiation)|absorptivity]] quickly deepening the hole. As the hole deepens and the material boils, vapor generated erodes the molten walls blowing ejection out and further enlarging the hole. Nonmelting materials such as wood, carbon, and thermoset plastics are usually cut by this method.

===Melt and blow===
Melt and blow or fusion cutting uses high-pressure gas to blow molten material from the cutting area, greatly decreasing the power requirement. First, the material is heated to melting point then a gas jet blows the molten material out of the kerf avoiding the need to raise the temperature of the material any further. Materials cut with this process are usually metals.

===Thermal stress cracking===
Brittle materials are particularly sensitive to thermal fracture, a feature exploited in thermal stress cracking. A beam is focused on the surface causing localized heating and thermal expansion. This results in a crack that can then be guided by moving the beam. The crack can be moved in order of m/s. It is usually used in the cutting of glass.

===Stealth dicing of silicon wafers===
((further|Wafer dicing))
The separation of [[microelectronic]] chips as prepared in [[semiconductor device fabrication]] from [[wafer (electronics)|silicon wafers]] may be performed by the so-called stealth dicing process, which operates with a pulsed [[Nd:YAG laser]], the wavelength of which (1064&nbsp;nm) is well adapted to the electronic [[band gap]] of [[silicon]] (1.11 [[Electronvolt|eV]] or 1117&nbsp;nm).

===Reactive cutting===
Reactive cutting is also called "burning stabilized laser gas cutting" and "flame cutting". Reactive cutting is like oxygen torch cutting but with a laser beam as the ignition source. Mostly used for cutting carbon steel in thicknesses over 1&nbsp;mm. This process can be used to cut very thick steel plates with relatively little laser power.

== Tolerances and surface finish ==
Laser cutters have a positioning accuracy of 10 micrometers and repeatability of 5 micrometers.((citation needed|date=September 2018))

Standard [[Surface roughness|roughness]] Rz increases with the sheet thickness, but decreases with laser power and [[cutting speed]]. When cutting low carbon steel with laser power of 800 W, standard roughness Rz is 10&nbsp;μm for sheet thickness of 1&nbsp;mm, 20&nbsp;μm for 3&nbsp;mm, and 25&nbsp;μm for 6&nbsp;mm.

<math display="block">Rz = \frac{ 12.528 \cdot S^{0.542} }{ P^{0.528} \cdot V^{0.322} }</math>

Where: <math>S =</math> steel sheet thickness in mm; <math>P =</math> laser power in kW (some new laser cutters have laser power of 4&nbsp;kW); <math>V =</math> cutting speed in meters per minute.<ref>((cite web|url=http://www.om.ugal.ro/AnnalsFasc8Tribology/pdf/2006/13-Annals2006-Radovanovic.pdf|title=Research on surface roughness by laser cut by Miroslav Radovanovic and Predrag Dašić|access-date=2010-03-10|archive-date=2016-03-03|archive-url=https://web.archive.org/web/20160303190350/http://www.om.ugal.ro/AnnalsFasc8Tribology/pdf/2006/13-Annals2006-Radovanovic.pdf|url-status=dead))</ref>

This process is capable of holding quite close [[Engineering tolerance|tolerances]], often to within 0.001&nbsp;inch (0.025&nbsp;mm). Part geometry and the mechanical soundness of the machine have much to do with tolerance capabilities. The typical surface finish resulting from laser beam cutting may range from 125 to 250 micro-inches (0.003&nbsp;mm to 0.006&nbsp;mm).<ref name="Todd, p. 186"/>

== Machine configurations ==
[[File:Dual Pallet Flying Optics Laser.jpg|thumb|Dual-pallet flying optics laser]]
[[File:Industrial 4kW laser with flying optics system.jpg|thumb|Flying optics laser head]]

There are generally three different configurations of industrial laser cutting machines: moving material, hybrid, and flying optics systems. These refer to the way that the laser beam is moved over the material to be cut or processed. For all of these, the axes of motion are typically designated X and Y [[Coordinate axis|axis]]. If the cutting head may be controlled, it is designated as the Z-axis.

Moving material lasers have a stationary cutting head and move the material under it. This method provides a constant distance from the laser generator to the workpiece and a single point from which to remove cutting effluent. It requires fewer optics but requires moving the workpiece. This style of machine tends to have the fewest beam delivery optics but also tends to be the slowest.

Hybrid lasers provide a table that moves in one axis (usually the X-axis) and moves the head along the shorter (Y) axis. This results in a more constant beam delivery path length than a flying optic machine and may permit a simpler beam delivery system. This can result in reduced power loss in the delivery system and more capacity per watt than flying optics machines.

Flying optics lasers feature a stationary table and a cutting head (with a laser beam) that moves over the workpiece in both of the horizontal dimensions. Flying optics cutters keep the workpiece stationary during processing and often do not require material clamping. The moving mass is constant, so dynamics are not affected by varying the size of the workpiece. Flying optics machines are the fastest type, which is advantageous when cutting thinner workpieces.<ref>((Cite book|url=https://books.google.com/books?id=pRah71xUxbMC&pg=PA38|title=Laser Cutting Guide for Manufacturing|last=Caristan|first=Charles L.|date=2004|publisher=Society of Manufacturing Engineers|isbn=9780872636866|language=en))</ref>

Flying optic machines must use some method to take into account the changing beam length from the near field (close to the resonator) cutting to the far field (far away from the resonator) cutting. Common methods for controlling this include collimation, adaptive optics, or the use of a constant beam length axis.

[[Multiaxis machining|Five and six-axis machines]] also permit cutting formed workpieces. In addition, there are various methods of orienting the laser beam to a shaped workpiece, maintaining a proper focus distance and nozzle standoff, etc.

=== Pulsing ===
[[Pulsed lasers]] which provide a high-power burst of energy for a short period are very effective in some laser cutting processes, particularly for piercing, or when very small holes or very low cutting speeds are required, since if a constant laser beam were used, the heat could reach the point of melting the whole piece being cut.

Most industrial lasers have the ability to pulse or cut CW (continuous wave) under NC ([[numerical control]]) program control.

Double pulse lasers use a series of pulse pairs to improve [[material removal rate]] and hole quality. Essentially, the first pulse removes material from the surface and the second prevents the ejecta from adhering to the side of the hole or cut.<ref>(( cite web |author= Forsman, A|url= //fusion.gat.com/pubs-ext/miscpubs/A25867.pdf | title = Superpulse A nanosecond pulse format to improve laser drilling |publisher= Photonics Spectra |date= June 2007 |access-date= June 16, 2014 |display-authors=etal))</ref>

== Power consumption ==
The main disadvantage of laser cutting is the high power consumption. Industrial laser efficiency may range from 5% to 45%.<ref>http://www.laserline.de/tl_files/Laserline/downloads/broschueren/en/Laserline_Image_high_power_diode_laser.pdf - Page 4:"High electrical/optical efficiency of up to 45%"</ref> The power consumption and efficiency of any particular laser will vary depending on output power and operating parameters. This will depend on the type of laser and how well the laser is matched to the work at hand. The amount of laser cutting power required, known as ''heat input'', for a particular job depends on the material type, thickness, process (reactive/inert) used, and desired cutting rate.

{| class="wikitable"
|+ Amount of heat input required for various materials at various thicknesses using a ((CO2)) laser [watts]<ref>((harvnb|Todd|Allen|Alting|1994|p=188)).</ref>
|-
! rowspan=2 | Material
! colspan=5 | Material thickness
|-
| 0.51&nbsp;mm
| 1.0&nbsp;mm
| 2.0&nbsp;mm
| 3.2&nbsp;mm
| 6.4&nbsp;mm
|-
! Stainless steel
| 1000
| 1000
| 1000
| 1500
| 2500
|-
! Aluminium
| 1000
| 1000
| 1000
| 3800
| 10000
|-
! Mild steel
| −
| 400
| −
| 500
| −
|-
! Titanium
| 250
| 210
| 210
| −
| −
|-
! Plywood
| −
| −
| −
| −
| 650
|-
! Boron/epoxy
| −
| −
| −
| 3000
| −
|}

== Production and cutting rates ==
The maximum cutting rate (production rate) is limited by a number of factors including laser power, material thickness, process type (reactive or inert), and material properties. Common industrial systems (≥1&nbsp;kW) will cut carbon steel metal from ((nowrap|0.51 – 13 mm)) in thickness. For many purposes, a laser can be up to thirty times faster than standard sawing.<ref>((Cite web|url=http://www.laserage.com/laser-cutting/|title=Laser Cutting|website=Laserage|language=en-US|access-date=2016-08-23|archive-date=2018-04-28|archive-url=https://web.archive.org/web/20180428185057/http://www.laserage.com/laser-cutting/|url-status=dead))</ref>

{| class="wikitable"
|+Cutting rates using a ((CO2)) laser [cm/second]
|-
! rowspan=2 | Workpiece material
! colspan=6 | Material thickness
|-
| 0.51&nbsp;mm
| 1.0&nbsp;mm
| 2.0&nbsp;mm
| 3.2&nbsp;mm
| 6.4&nbsp;mm
| 13&nbsp;mm
|-
! Stainless steel
| 42.3
| 23.28
| 13.76
| 7.83
| 3.4
| 0.76
|-
! Aluminium
| 33.87
| 14.82
| 6.35
| 4.23
| 1.69
| 1.27
|-
! Mild steel
| −
| 8.89
| 7.83
| 6.35
| 4.23
| 2.1
|-
! Titanium
| 12.7
| 12.7
| 4.23
| 3.4
| 2.5
| 1.7
|-
! Plywood
| −
| −
| −
| −
| 7.62
| 1.9
|-
! Boron / epoxy
| −
| −
| −
| 2.5
| 2.5
| 1.1
|}

== See also ==
((div col|small=yes))
* [[Craft]]
* [[3D printing]]
* [[Drilling]]
* [[Laser ablation]]
* [[Laser beam machining]]
* [[Laser beam quality]]
* [[Laser converting]]
* [[Laser drilling]]
* [[Laser engraving]]
* [[List of laser articles]]
* [[Mirror galvanometer]]
* [[Water jet cutter]]
((div col end))

== References ==
((reflist))

== Bibliography ==
* (( cite book | last = Bromberg | first = Joan | title = The Laser in America, 1950-1970 | publisher = MIT Press | page = 202 | year = 1991 | url = https://books.google.com/books?id=P6Ta1MPiOM8C&pg=RA1-PA202 | isbn = 978-0-262-02318-4 ))
* (( cite book | last1=Oberg  | first1=Erik | last2=Jones  | first2=Franklin D. | last3=Horton | first3=Holbrook L. | last4=Ryffel | first4=Henry H. | title = Machinery's Handbook | publisher = Industrial Press Inc | edition = 27th | year = 2004 | location = New York, NY | isbn = 978-0-8311-2700-8 ))
* (( cite book | first1 = Robert H. | last1 = Todd | first2 = Dell K. | last2 = Allen | first3 = Leo | last3 = Alting | year = 1994 | title = Manufacturing Processes Reference Guide | publisher = Industrial Press Inc. | url = https://books.google.com/books?id=6x1smAf_PAcC | isbn = 0-8311-3049-0 ))

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Module:Footnotes (view source) (template editor protected)
Module:Footnotes/anchor id list (view source) (template editor protected)
Module:Footnotes/anchor id list/data (view source) (template editor protected)
Module:Footnotes/whitelist (view source) (template editor protected)
Module:Format link (view source) (template editor protected)
Module:Hatnote (view source) (template editor protected)
Module:Hatnote/styles.css (view source) (template editor protected)
Module:Hatnote list (view source) (template editor protected)
Module:Icon (view source) (template editor protected)
Module:Icon/data (view source) (template editor protected)
Module:Labelled list hatnote (view source) (template editor protected)
Module:Message box (view source) (protected)
Module:Message box/ambox.css (view source) (protected)
Module:Message box/configuration (view source) (protected)
Module:Namespace detect/config (view source) (protected)
Module:Namespace detect/data (view source) (protected)
Module:Navbar (view source) (protected)
Module:Navbar/configuration (view source) (protected)
Module:Navbar/styles.css (view source) (protected)
Module:Navbox (view source) (template editor protected)
Module:Navbox/configuration (view source) (template editor protected)
Module:Navbox/styles.css (view source) (template editor protected)
Module:Navbox with collapsible groups (view source) (template editor protected)
Module:Pagetype (view source) (protected)
Module:Pagetype/config (view source) (protected)
Module:Pagetype/disambiguation (view source) (protected)
Module:Pagetype/setindex (view source) (protected)
Module:Pagetype/softredirect (view source) (protected)
Module:SDcat (view source) (protected)
Module:String (view source) (protected)
Module:Unsubst (view source) (protected)
Module:Wikitext Parsing (view source) (protected)
Module:Yesno (view source) (protected)

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Retrieved from "https://en.wikipedia.org/wiki/Laser_cutting"