Which metal cutting service is best for you?
There are many methods you could choose to cut metal. The best one for you depends on several factors, the two main ones being the thickness of the metal and the intricacy of the components you require. Is laser cutting the right metal cutting service for your needs? Or should you choose plasma or water jet cutting instead?
Below we explain how each popular metal cutting service works and compare their pros and cons.
HOW DOES LASER CUTTING WORK?
Laser cutting is a process which works by directing a concentrated beam of light (the laser), to cut shapes out of your chosen material, in this case metal. The metal then melts, burns, vaporises or is blown away, leaving a high-quality cut edge.
Fibre laser cutting technology cuts more complex shapes and small diameter holes at similar or faster speeds than other metal cutting methods.
HOW DOES PLASMA CUTTING WORK?
Plasma cutters work by sending a pressurised gas, such as nitrogen, argon, or oxygen, through a narrow channel. In the centre of the channel there is a negatively charged electrode. Power is applied to the negative electrode and the tip of the nozzle touches the metal, the connection creates a circuit. A powerful spark is generated between the electrode and the metal generating immense heat which cuts through your chosen material.
HOW DOES WATER JET CUTTING WORK?
A waterjet cutter is capable of slicing through metal or other materials using a jet of water at extremely high pressure and velocity. For some materials just water is used, but metal requires a mixture of water and an abrasive substance, usually crushed garnet. Each abrasive grain that passes through wears away a little bit of the material. Because each abrasive particle only removes a tiny amount of material, very little heat is generated. Also any heat that is produced is quickly cancelled out by the stream of water. The constant momentum of the water stream keeps the abrasive particles moving in a straight line after they exit the focusing tube. As a result the cut edge is extremely straight and accurate.
Some waterjet cutting machines can cut metal up to 300mm thick.
Mechanical cutting
The definition of mechanical cutting is when a cutting head or blade is in physical contact with the material during the cutting process. It covers everything from a handsaw to drill presses, lathes and CNC milling machines. The main disadvantage to mechanical cutting methods is that the cutting edge or head deteriorates constantly as it cuts, leading to a variation in the quality and accuracy of the cut edge. The physical contact of the cutting head or blade also generates heat caused by friction which can distort or affect the properties of the material being cut.
Laser, waterjet and plasma cutting are all superior to mechanical cutting methods in precision and quality of the cut edge because the quality of the cut remains consistent.
Metal CUTTING METHOD PROS AND CONS
Laser, plasma and waterjet cutting all over a more refined and consistent cut edge compared to mechanical cutting methods because there is no contact with the material, giving a more precise cut whose quality does not deteriorate.
Laser cutting is one of the most precise methods offered as a metal cutting service with a tolerance of just +/-0.25mm. It is well suited to cutting small and detailed components from thinner sheet metal. Laser cutting requires little clean up, a small amount of waste is produced in the form of dust, which is quickly removed. A few years ago laser cutting machines could not cut through shiny or reflective metals, but modern machines such as those used by Lasered Components, are able to with ease. The main disadvantage is that commercial metal laser cutters cannot cut the same thickness of metal as commercial waterjet or plasma cutters.
The most important advantage waterjet cutting boasts is its ability to cut material without generating heat. This means that metals can be cut without changing their properties or warping the components. Waterjet cutting is not suited to cutting small, thin parts due to the high level of force involved. Another disadvantage of waterjet cutting is that the abrasives mixed in the water require special disposal due to possible toxicity, which not only has environmental repercussions, but also adds to the running costs.
Plasma cutters have a smaller kerf* compared to laser machines, meaning less metal is lost during profiling. However, the tolerance of a plasma cutter is slightly less than that of a laser cutting machine. Plasma produces a cut edge that is as smooth as laser cut edge, but it is handicapped by a slight bevel of 4 – 5 degrees in the cut face.
Generally speaking, plasma cutting machines are more widely suited to cutting thick sheet and plate metal. The most modern plasma machines are capable of cutting through metal of a thickness of up to 150mm. In comparison, laser cutters are better suited to thinner sheet metals or more intricate components.
*Kerf - the width of the cut made by a device such as a saw or a laser. The term is also sometimes used to describe the thickness of a cutting blade.
Below is a table outlining the key capabilities, pros and cons of each commercial metal cutting service:
| Waterjet Cutting | Plasma Cutting | Laser Cutting |
|---|---|---|
| + Excellent for high volume production | + Excellent for high volume production | |
| + Can cut shiny / reflective metals | + Can cut shiny / reflective metals | + Can cut shiny / reflective metals |
| – Limited automation | – Limited automation | + Highly automated |
| Up to 300mm thick metal plate | Up to 150mm thick metal plate | Up to 25mm thick metal plate |
| + Doesn’t generate heat | – Heats the edge as it cuts | – Heats the edge as it cuts |
| + Fastest cutting method | ||
| + Narrow kerf | + Highest tolerance | |
| – 4-5 degree bevel in cut edge | ||
| – Not suited to small or thin components | + Excellent for small or thin components | |
| – Highest operating cost | ||
| – Complex clean up and harmful waste | + Minimal waste | + Minimal waste |
Below is a list outlining the key capabilities, pros and cons of each commercial metal cutting service:
Waterjet cutting
+ Can cut shiny / reflective metals
+ Limited automation
+ Upto 300mm thick metal plate
+ Doesn’t generate heat
– Not suited to small or thin components
– Highest operating cost
– Complex clean up and harmful waste
Plasma Cutting
+ Excellent for high volume production
+ Can cut shiny / reflective metals
+ limited automation
+ Upto 150mm thick metal plate
– Heats the edge as it cuts
+ Narrow kerf
– 4-5 degree bevel in cut edge
+ Minimal clean up
Laser cutting
+ Excellent for high volume production
+ Can cut shiny / reflective metals
+ Highly automated
+ Upto 25mm
– Heats the edge as it cuts
+ Fastest cutting method
+ Highest tolerance
+ Excellent for small and thin components
+ Minimal clean up
In Summary
Consider the specific requirements for your specific project, to decide which metal cutting service will suit you best. The physical things to consider are the thickness of material and the level of detail required, alongside the logistical aspects of cost and turnaround time.
The best way to find out if laser cutting is the right metal cutting service for you is to send your enquiry to sales@lasered.co.uk or, if you have any questions, please contact our sales team on 01376 327182.
Fast Quotes
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To get a competitive laser cutting cost for your next project, don’t hesitate to contact us. We aim to answer quotes sent between 7.30am and 4pm within one hour. Outside these hours we will respond the next working morning.
We accept DXF, DWG and NC files, please send information about which material, thickness and quantities you require.
Please note: We are unable to provide quotes or prices over the phone, please email us your requirements and we will respond as quickly as possible.