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If you’re passionate about metal cutting or just keen to learn more, you’ve landed in the right place.
For over 38 years, Amber Steel has been at the forefront of metal cutting services, specializing in laser cutting, flame cutting, and plasma cutting. Our expertise has carved a niche in this cutting-edge industry, delivering precision and excellence across industrial projects big and small.
In our blog, we’ll share a mix of useful tips, innovative applications, our thoughts on sustainability in steel cutting, and more. Expect stories from the cutting floor, insights into how our processes can streamline projects across industries, and a few lessons we’ve learned along the way.
While we keep some of our trade secrets under wraps, this blog is designed to offer valuable nuggets of wisdom that you simply won't find anywhere else. Whether you’re a professional in the industry or someone fascinated by the possibilities of metal cutting, you'll find something of value here.
So, stick with us as we delve into the finer points of metal work. We’re glad to share our insights and lead discussions that matter to our industry.
How precision metal cutting propels the aerospace industry, from constructing lighter frames to enhancing aerodynamics.
The role of advanced metal cutting in automotive manufacturing, driving innovations in vehicle design and efficiency.
All about the robust and versatile process of flame cutting, ideal for tackling thicker metals with precision and ease.
Discover the art of crafting metal furniture, where cutting techniques meet design to create both functional and aesthetic pieces.
A behind-the-scenes look at the mechanics of metal cutting technologies and the science that makes them tick.
Laser cutting is where extreme precision meets efficiency, allowing for intricate designs and clean finishes.
The critical role of precise steel cutting in developing reliable and intricate medical devices.
How steel cutting supports the oil and gas industry with components that withstand extreme environments and pressures.
Known for its speed and versatility, plasma cutting slices through conductive metals with hot plasma.
Safety first! Tips and insights on maintaining a safe environment while handling powerful metal cutting equipment.
The backbone of construction, where steel fabrication and cutting technologies create frameworks that shape skylines.
Sustainability
A look at sustainability in metal cutting, focusing on practices that reduce waste and conserve energy to protect our planet.
In the automotive industry, innovation is crucial for staying ahead and producing accurate results. As the industry evolves, a revolutionary method in automotive OEM production is laser blanking–a cutting-edge process offering unparalleled precision and flexibility.
Amber Steel is a leading metal-cutting provider specializing in providing the best solutions for your manufacturing needs. In this blog, our experts explore how laser blanking technology transforms automotive OEM production, saving time and costs while going above the demands of modern vehicle manufacturing.
Laser blanking is a modern approach to manufacturing where a laser is implemented by cutting flat pieces of metal, known as blanks, to create precise shapes and sizes. Traditional blanking methods typically use mechanical punches and dies. With this innovation, laser blanking uses computer systems that guide laser beams to make intricate and accurate cuts in automotive OEM production.
Laser blanking technology was first introduced in the early 1970s in the metalworking industry. At the start, lasers were first mounted to oxy-fuel cutting machines. With time and further adjustments, the potential of laser blanking quickly became evident.
Here is a breakdown of the evolution of laser blanking throughout history:
1970s: The 500-watt CO2 laser was introduced, creating the beginning of laser technology in metalworking. Even though early applications were limited, laser technology still proved useful in cutting complex shapes, which revolutionized the way sheet metal was fabricated.
1990s: During this period, the concept of laser blanking became known globally. Many companies started adopting this new technology into their manufacturing processes and began replacing traditional blanking presses with coil-fed laser cutting systems. The workings of modern laser blanking led to enhanced efficiency and flexibility.
2000s: With new advancements, fiber laser technology was introduced which significantly increased the speed of laser blanking. High-brightness fiber lasers created faster cutting speeds and meticulous cuts, making laser blanking the most viable option for mechanical stamping presses.
Initial Experiments: At first, lasers were integrated into previous existing cutting machines to provide precision and accuracy with more traditional methods. These experiments showed that lasers could achieve better cutting results on their own instead of being add-ons to older machines.
Multicompany Usage: A variety of companies decided to implement laser blanking into their practices. This collaboration explored the feasibility of replacing blanking presses with laser systems, which led to the development of coil-fed laser cutting.
Technological Advancements: The 2000s is when laser cutting significantly improved by introducing high-brightness fiber lasers. These new updates provided faster and more precise cuts, enabling manufacturers to produce high-quality blanks at lower costs, and faster schedules.
Laser blanking has revolutionized the way manufacturers process metal blanks. Since its introduction, with experimentation and collaboration, laser blanking has evolved to create more efficient results. Amber Steel continues to strategically use this modern form of technology, providing cutting-edge later blanking services to meet the diverse needs of the automotive industry.
Original Equipment Manufacturers (OEMs) in the automotive industry are companies that produce parts and equipment that may be marketed by another manufacturer, said manufacturer here being Amber Steel. Automotive OEM production involves the creation of essential vehicle components, which are then assembled into a vehicle by automakers. Since there are strict safety guidelines for the creation of vehicle parts, blanking services must use precision, efficiency, and adaptable designs to meet the diverse needs of the automotive market.
An important facet of laser blanking is its improved formability of metal blanks, which is crucial for the stamping process of automotive parts to fit together during the assembling process:
Contoured Blanks: Laser blanking can create contoured blanks, which results in the look and feel of smooth, curved edges rather than sharp corners. The best method to obtain a contoured shape is to use a stamping press with lasers. This method reduces the risk of material failure.
Enhanced Drawing Processes: A computer-guided laser cutting system easily allows for tweaking blanks and shapes. Complex shapes can effortlessly be drawn, which proves to be a better option than traditional blank outcomes.
Consistent Quality: The need for exact specifications in automotive production is what makes laser blanking the most applicable method. Its ability to consistently provide quality, and exact measurements allows the stamping process to run smoothly.
Since there are a variety of different vehicle models, with newer ones each year, it is important for the automotive industry to utilize a blanking process that can adjust to these demands:
Rapid Design Changes: With laser blanking, manufacturers can quickly adapt to new vehicle designs, eliminating the use of dies. This process streamlines rapid prototyping and allows manufacturers to put new models on the market faster.
Variety of Geometrics: Different vehicles have diverse needs when it comes to creating parts to assemble. Laser blanking's flexibility can accommodate these needs. Whether it's a simple panel or a complex structural part, laser blanking can handle the task with ease.
Scalability: As the demands for different vehicle structures change, laser blanking systems can easily scale production rates according to the needs of the automotive industry. This adaptable approach ensures that manufacturers get the right amount of product.
The impact of laser blanking during automotive parts production makes it the most qualified system to receive the best results. Integrating laser blanking technology improves the production process, reduces costs, and maintains quality. Amber Steel continues to implement these advantages by using laser blanking to meet the evolving standards of the automotive OEM production industry.
One of the many benefits that set laser blanking apart from traditional manufacturing methods is its precision and flexibility for automotive OEM production:
Detailed and Complex Shapes: Without the need for mechanical punches and dies, laser blanking uses computer-guided laser technology to create intricate patterns. This results in smooth, precise edges that are difficult to achieve with traditional methods. Laser blanks meet the exact specifications for automotive OEM production without further adjustments.
Design Versatility: Laser blanking can easily switch designs with computers instead of physical die changes. This allows manufacturers to quickly make edits to exact specifications, resulting in less time for projects involving various parts.
Optimization of Material Use: Waste is minimized by strategically nesting parts of sheet metal for optimal space. This not only leads to a more sustainable practice but also provides savings on material costs.
Modern laser blanking lines typically exceed the speed of traditional press-based blanking. These results far outweigh old practices with:
High-Speed Cutting: the advancement in fiber laser technology has greatly increased cutting speeds. Modern laser blanking systems can cut metal at remarkable speeds, making them almost superior to mechanical stamping presses. Its fast technology is ideal for automotive production, especially due to the demands of manufacturing multiple shapes.
Continuous Operation: Laser blanking lines can operate continuously, reducing the time it takes to change dies and specifications. With the minimization of interruptions and the involvement of high-speed cutting, manufacturing processing times are significantly reduced.
Toolless Operation: The absence of having to physically change dies means there is no need for die maintenance, storage, or die changes, which can reduce maintenance and product costs.
The advancements of laser blanking are versatile and have led to the ability to cut through thicker steels and other challenging materials without a struggle:
High-Strength Steels: As the automotive industry moves toward lighter and stronger materials, the need for laser blanking has become more pressing. Its ability to cut through high-strength steels with ease and prevent materials from wearing down proves it a better replacement for previous forms of metal shaping.
Thickness and Grade Variability: Laser blanking is suitable for a wide range of materials. It focuses on the thickness of a material and its absorbable laser energy. This practice is ideal for various materials, including aluminum sheets or thick, high-strength steel plates.
Consistent Quality: The precise control of laser blanking provides quality cuts among different variations of materials and thickness. The high standards that laser cutting provides are perfect for automotive manufacturing, where each component must meet strict quality requirements.
Laser Blanking offers a modern approach to automotive OEM production that has significantly benefited the industry. Its advantages have evolved significantly, creating low costs, reduced times, improved formability, and exceptional adaptability. This new laser technology creates high-quality, intricate blanks using versatile and efficient techniques and has become the most ideal method for the demanding needs of the automotive industry. The future of laser blanking looks promising, with newer, more revolutionized applications, its potential to extend beyond automotive manufacturing could prove beneficial for other lines of work.
Contact us today to learn more about how Amber Steel can benefit your business with modern laser blanking technology. Discover how our services can improve your production efforts and drive innovation in your manufacturing processes.
Competition is rampant in automotive manufacturing unless you’re one of Canada's four heavyweights in the sector. Even the massive players must do everything possible to stay ahead of the game, as there’s a constant struggle for supremacy.
You’ve always got to be looking for a competitive edge in the automotive world.
Sometimes, marketing, sales, or other abstract business growth strategies make the difference. Most of the time, however, lasting success comes down to the nitty-gritty of assembly processes.
In other words, are your manufacturing approaches, techniques, and technologies more efficient than your competition?
Laser cutting is a prominent example of technology giving automotive manufacturing businesses a competitive edge. It’s revolutionized the sector due to its vast benefits, leading to its widespread implementation.
In this post, we’ll break down the applications and benefits of laser cutting in the auto manufacturing sector.
Aside from having numerous flexible applications (e.g., fabricating metal components, cutting plastic parts, and branding-related engraving/marking), laser cutting can integrate with robotic systems. The streamlined results have yielded a more cost-effective and functionally efficient sector.
As your “total source” service for producing high-quality steel products, we apply the most suitable techniques to each project. We invest in cutting-edge technology and equipment to ensure there’s always a solution for our clients, whether straightforward or alternative, helping them achieve all specifications and tolerances.
Contact us today if you’re mulling over a project in your mind or wish to learn more about steel cutting.
CO₂ and fibre lasers are the two most regularly featured in the automotive manufacturing industry, offering the desired balance of accuracy, speed, and budget-friendliness.
Typically, CO₂ lasers cut non-metallic materials (i.e., plastic, fabrics, and rubber). Their versatility lends itself to the precise cutting of intricate patterns and shapes. These lasers fit seamlessly into high-volume production scenarios because they’re efficient, fast, and accurate. They’re also low maintenance, speaking further to their ability to streamline production.
The material being cut, precision/accuracy-based needs, and production volume all impact your choice of laser cutter. Consistency, reliability, and speed are all necessary to meet the demands of this fast-moving, competitive sector.
Here’s a list of car parts that often undergo laser cutting during manufacturing:
Doors.
Dashboards.
Bumpers.
Interior panels.
Car seats.
Engine components.
Below, we’ll delve further into laser cutting’s role in automotive manufacturing and how it streamlines the processes throughout the industry.
Laser cutting is implemented to cut the following plastic parts:
Interior panels and dashboards.
License plates.
Bumpers.
Pillars.
Light housings.
Trims.
Spoilers.
Etc.
Automotive components are constructed with a diverse array of plastics, such as acrylic, HDPE, ABS, polycarbonate, TPO, and polypropylene.
Whether plain or painted, plastics can be integrated with carbon/glass-fibre-reinforced support systems, fabric-covered interior pillars, and other such materials.
The injection moulding process yields extra plastic residue, which laser cutting can trim. Furthermore, lasers can drill or cut holes for parking sensor lights, switches, fixing points, and other components.
Textiles like upholstery fabrics are a frequent fixture of a car’s interior. The fabric type and thickness will dictate the processing speed for manufacturing these materials.
Precision cuts are used for most synthetic textiles, and the edges are sealed, offsetting any fraying when seats are assembled and stitched.
Accurate Airbag and Seatbelt Sealing and Cutting
Conventional cutting methods are prone to wear and tear when used for airbag sealing.
Conversely, laser cutting seals airbags while reducing the likelihood of wear.
Before being stitched together, flat-woven airbag materials are shaped with a laser cutter. They’re also silicone-coated for optimal permeability.
A laser cutter is also best suited to one-piece-woven (OPW) airbags because they require trimming.
In these scenarios, there’s no contact and fabric handling is limited, preventing damage that could hamper the structural integrity of an airbag.
Metal parts such as hoods, body panels, doors, and fenders often undergo laser cutting. As are gears, shafts, bearings, and other engine components.
Laser cutting is also used when manufacturing suspension components and exhaust systems.
The automotive industry's ongoing shift towards lighter, stronger materials for better fuel efficiency and performance has made laser cutting even more critical. Materials such as high-strength steel, aluminum alloys, and composites require the precise and delicate handling that laser cutting offers.
This technology is particularly adept at cutting complex shapes and small, precise features in these advanced materials, which are often challenging to process using traditional methods.
Laser cutting minimizes the risk of material deformation or damage, often a concern with conventional cutting methods, particularly when working with delicate or thin metals. The contactless nature of laser cutting means there's less mechanical stress on the material, resulting in cleaner edges and a higher-quality finish.
With that said, laser cutting is not always the best way to cut metal automotive parts:
When it comes to thick metal sheets, plasma cutting is more effective and faster. This is the case for certain structural components of a vehicle’s frame, suspension, and exhaust system.
For very thick steel plates, like heavy-duty chassis components for commercial vehicles, construction equipment, or heavy trucks, flame cutting is the way to go.
Commonly, leather (synthetic or authentic) is cut with lasers because of how fine-tuned the process and machinery are.
This section will focus on the benefits of laser cutting in automotive manufacturing.
The computer numerical controls (CNC) in laser cutters enable them to cut precisely preprogrammed outlines.
Automotive manufacturing companies continually rely on laser cutting as its features (like CNC) streamline production with consistent, never-changing parts, reducing the time needed to complete work.
Glass, rubber, fabrics, and plastics all have their place in automotive manufacturing and can all be cut with lasers.
Laser-cut components and materials exist in almost every car’s exterior and interior. More to the point, laser cutting is implemented throughout automotive manufacturing, from earlier designs to development and assembly.
Using a high-density heat source, laser cutters produce clean and precise results.
Also, laser cutters produce a light wave with a wavelength of 10,000 nm. The metal’s partial energy absorption makes precision cutting a reality since it yields a molecular structure change in the metal.
Beam quality is assessed with the beam parameter product (BPP). For example, CO₂ lasers have an 8-9mm BPP. This combines with intensely concentrated heat, yielding near flawless cuts, explaining the widespread usage throughout automotive manufacturing.
Often, laser cutters find themselves a crucial component of airbag sealing and cutting, producing error-free results, which is why they’re sought-after throughout the sector.
Here, we’ll introduce the concept of output-to-space efficiency and how optimizing it benefits automotive manufacturers.
Compared to its throughput, laser cutters are compact, even relatively small. Thus, they can be seamlessly integrated into a manufacturing setting, not taking up much space. As such, they’ll fit into smaller shops as much as larger spaces, maintaining the utmost precision and highest quality.
Every stage of automotive manufacturing—from the design phase until assembly—benefits from laser cutters due to such machines' accuracy, speed, and precision.
Integration capabilities with robot systems (because of the 3D nature of some items) make lasers even more of a streamlining tool.
Some robots can pick up parts, offer them to a processing head, and maneuver them to complete the cut.
A laser can also be installed on a robot arm, enabling the beam to move around a part’s 3D contours.
Wide ranges of processes can be implemented when the above techniques are combined. Workpieces and laser heads are managed and streamlined to execute cutting operations optimally.
Several laser processes can be completed within one robot cell, improving production and cycle times. Processing quality, repeatability, and dependability are all enhanced, lowering rejection rates and reducing expensive material waste. Thus, laser cutters serve large-batch and small-scale productions alike.
Are you an automotive parts manufacturer seeking speed, precision, accuracy, dependability, and adaptability?
Laser cutting can make all the difference in the world to your enterprise. It’s already an integral component of automotive manufacturing because of the streamlining qualities discussed above.
Regardless of the components that laser cutting can help manufacture, it’ll generate top-tier results and products on which your company can rest their reputation.
This versatile form of steel-cutting fits into almost all manufacturing environments, including small shops. Yet, it entirely fits into larger-scale settings. It’s compact, seamless, and can integrate with robotic systems to further streamline production.
Amber Steel specializes in plasma, flame, and laser cutting, offering your enterprise a “total source” solution to produce top-tier steel products, including automotive manufacturing parts. We’re committed to investing in cutting-edge technology and equipment to ensure our clients have alternatives to achieve bespoke specifications and tolerances.
Learn more about steel cutting by contacting us today. Or, reach out with an email or phone call if you have a project in mind and wish to discuss it with industry experts.
