We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
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.
Laser cutting – a process that, not surprisingly, uses laser energy to cut through various materials. We’ve written extensively on the subject, but something we’ve yet to touch on is the importance of parts design and best practices for laser cutting efficiency.
Laser cutting is a non-contact process that results in extremely accurate and dimensionally cut materials. By its very principle, it works through melting and burning through the material in question. A jet of air then blows away the melted materials, leaving behind a clean and smooth surface free from debris and sharp edges.
Despite the laser cutting process being precise and cost-effective, there are several design tips to consider before you move on to your next project. These considerations are essential for those operating in the industry, and luckily, Amber Steel has all the tips and tricks you need.
Preparing your part design for production saves both time and ensures your final product lives up to both expectations and industry regulations. Luckily, optimizing your part design isn’t complicated in theory.
Before you begin your next project, check for these common design flaws:
First, ensure your file is two-dimensional and in vector format. All objects must be on the same layer, and you must remove any stray points, complicated lines, or empty objects. Make sure to check for accidentally intersecting lines and use inch units at a 1:1 scale.
If shapes aren’t properly connected end to end, then the laser isn’t going to be able to follow the path the way you want. You should review your file in Outline mode (depending on your chosen design software) to ensure these missed areas are easier to spot.
Everything can impact your project, including the material thickness, which directly affects how detailed your design is. The thickness could range from 1 to 10 mm (about 0.39 in). For example, engravings require a material thickness that isn’t too thin to achieve the best results.
Otherwise, the laser could very well cut through the material, resulting in poor or even failed end-product. That said, if your project intends to use more flexible parts, then a thin material could be a great choice. Consider your project.
Laser cutters generally only support vector files. Vector files refer to digital graphics that are defined using mathematical formulas (or vectors) rather than pixels.
Designs that don't utilize vectorized drawings can pose an issue when it comes to laser cutting, as they simply aren't adequate when it comes to creating an object using laser cutting. The reason is the lack of necessary information required to enable the machines to be able to cut or engrave. This is where vector files come in.
Vector files are essential for achieving precipice and scalable products. Laser cutting machines rely on vector paths to guide the laser accurately during the cutting, scoring, and engraving. This ensures the cutting path is executed smoothly and eliminates jagged edges, producing clean and precise products.
Kerf is the small amount of material that vaporizes during the laser cutting process, leaving a gap. This phenomenon is similar to other cutting methods, such as using a blade on wood, where the thickness of the blade affects the cut. Laser beams also have thickness, contributing to kerf when they burn through materials.
Laser cutting is valuable for creating parts that fit together precisely in assembly. To ensure a good fit, designers must account for the kerf. Start by subtracting half the kerf size from the outer frame and add the remaining half to the inner sections.
Selecting the right node positions is crucial for parts that need to remain connected after assembly. Nodes concentrate friction at specific points, preventing parts from easily coming apart. Placing nodes opposite each slot and adjusting their number according to slot length reduces tension and ensures smooth interlocking.
Node width should match the material's density, with denser materials requiring narrower nodes to optimize the laser cutting process.
Choosing the right part shape is essential for efficient laser cutting. For example, sharp 90-degree corners can decrease cutting quality as the laser slows down and may cause burning or material loss.
Opting for larger radius corners allows for smoother transitions, faster cutting speeds, and improved part quality. These design considerations are critical to minimizing production costs and maximizing efficiency.
When it comes down to design practices, there are several different considerations to take into account:
When you use a laser to process parts, you must be aware that a high-intensity light source generates a laser beam so hot that it can melt metal in a fraction of a second. Subsequently, any part you process with a laser is exposed to extreme heat, creating a heat-affected zone (HAZ) along the cut's edge.
As far as fabricators are generally concerned, this HAZ is a non-issue, but in other fields – such as aeronautics (study of the science of flight) – it can pose several issues. There are critical parts in these industries that are typically not laser cut because the design engineers can’t take the risk that the metal can develop micro fissures that could create a problem in the future.
Any laser-processed part needs to have a taper of some sort because the laser beam is not usually perfectly shaped; rather, it’s more like an hourglass. When using thinner materials, the taper is so minimal that it usually isn’t a problem, but it can become one when the material gets thicker.
Fabricators must consider tapering when the machine tool builders have developed technology that improves cut quality, all while reducing the taper amount in thicker materials.
The primary advantage of using a laser to process sheet metals is it can create any conceivable shape. The only real limitation to keep in mind is the part size. However, one consistent part design error is not properly considering bend reliefs drawn into parts.
Typically, with thin-gauge material, these reliefs are too thin to achieve a proper cut straight off the laser. This issue happens because the assist gas travels the path of least resistance, generally the first segment of the laser's path. When the laser travels back to the other side of the bend relief, the melted material isn't ejected properly, resulting in dross (impurities that form on the surface of metals during melting or processing) forming on the relief edge.
Whether using a traditional CO2 laser or solid-state laser, fabricators need to consider the same factors to ensure the reliability of the cutting process and achieve the maximum result.
For example, if the part is made with a 90-degree corner, the time needed for cutting increases the part quality. When laser cutting, the cutting head must slow down at sharp corners, which can lead to overburn and the formation of dross. In some cases, it may even completely burn away the corners. To mitigate this, design engineers should aim for larger corner radii whenever possible. This allows fabricators to enhance cutting speed and improves the quality of the parts produced.
Parts design is an essential part of the fabrication process, and ensuring the best possible efficiency for laser cutting involves considering it. Laser cutting technology has made strides over the last few years, but some things remain the same; the necessary working parts are all a part of the equation to the best possible result and shouldn’t be taken lightly.
Luckily for you, Amber Steel offers cutting-edge services, such as laser cutting, plasma cutting, flame cutting, and much more. Contact us for more information on how we can help you make the most out of your next fabrication project.
Many of our customers are looking for ways to operate more sustainably. We're right there with you. That's why we're excited to share how, believe it or not, laser cutting can help make steel fabrication a greener process.
Laser cutting might not be the first thing that comes to mind when you think "eco-friendly," but compared to traditional cutting methods, it offers many environmental advantages. It minimizes waste, uses less energy, and produces fewer harmful byproducts, resulting in a smaller overall impact on our planet.
But the benefits don't stop there. Laser cutting is incredibly efficient and precise, which means better quality products and cost savings for businesses. It's a win-win!
Let’s break down the basics of environmental sustainability and how it’s lending a hand to eco-friendlier practices in steel fabrication.
At Amber Steel, we specialize in laser, plasma and flame cutting and have always been a "total source" service for quality steel products. Quality is achieved by utilizing the right production technique for the right product.
Our continual investment in equipment and technology enables us to offer clients many production alternatives to achieve exact product specifications and tolerances. If you’re interested in learning more about steel cutting or have a project in mind that you would need our expertise on, do not hesitate to reach out! We’re always one email or phone call away.
First, let's consider some of the ways laser cutting minimizes ecological impact compared to traditional cutting methods.
Traditional cutting methods, like mechanical cutting or waterjet cutting, can be wasteful. They create wider cuts, rough edges, and inconsistencies, creating discarded material and unnecessary expenses.
Laser cutting, on the other hand, is incredibly precise. The focused laser beam makes clean, narrow cuts, ensuring parts are the exact size needed. This reduces material waste and avoids costly rework or scrap due to incorrect sizing.
The laser can also handle complex shapes and intricate details that other methods struggle with, further reducing waste. Over time, this translates into significant savings in material costs and a smaller environmental footprint.
The accuracy and consistency of laser cutting significantly reduces the amount of scrap produced compared to other cutting techniques. Even a small reduction in scrap per part adds up over large production runs, saving materials and money over time. For example, in a production run of 10,000 parts, the material savings just from laser cutting's precision can be significant!
Laser cutting is a naturally energy-efficient process. It works without touching the material, so there's no friction or wasted heat like with traditional sawing or milling. The laser beam focuses energy exactly where it's needed, which means less energy is lost in the process.
Plus, laser cutting is faster, so each job takes less time and energy overall.
The precision of laser cutting also plays a part. Clean, accurate parts also mean fewer mistakes and less wasted material, which further reduces energy use.
Modern laser cutting machines, especially those with fiber laser technology, are built to be even more efficient. They convert more electricity into usable laser power, and many have energy-saving features like standby modes.
Even when traditional cutting methods get the job done, they can be messy. Processes like sawing and drilling create a lot of friction and heat, which means they need coolants and lubricants to keep things running smoothly. Unfortunately, these substances aren't great for the environment or the people working with them.
Laser cutting offers a different approach. Because there's no physical contact between the laser and the metal, there's very little friction and heat. The laser focuses its energy on a tiny spot, leaving the rest of the material cool, which reduces the need for those potentially harmful coolants and lubricants.
By ditching the coolants, laser cutting creates a cleaner, safer workplace and reduces the amount of hazardous waste produced. It's a small change, but on a scale, it can have a big impact.
Traditional cutting methods can leave behind tiny bumps or burrs that can cause problems down the line. These might seem small, but they can affect how the part functions and require extra finishing work to fix. All of that adds up to more time, energy, and money spent on production.
Laser cutting creates clean, smooth cuts with far fewer burrs. The laser beam focuses its energy on a small area, melting and vaporizing the material with very little excess heat. Plus, we use a special gas to blow away any debris, resulting in even smoother edges and less chance of those pesky burrs forming.
The precision of laser cutting also means less risk of burrs caused by warping or distortion of the material. We have complete control over the laser beam, so it follows the cutting path perfectly, minimizing uneven edges where burrs like to hide.
With laser cutting, there's often fewer extra finishing steps to smooth out those rough edges. This translates to less energy and resources used, faster production, and lower overall costs.
Laser cutting's potential for sustainability goes even further. Forward-thinking manufacturers are finding new ways to make it even greener.
These eco-friendly approaches not only help the planet, but they often boost laser cutting’s efficiency and lower costs, too!
One exciting trend is the rise of recycled steel. It's a smart financial choice and governments often offer incentives for using it. Most importantly, recycled steel is largely just as strong and durable as brand-new steel.
Laser cutting is a perfect match for recycled steel. It can easily cut through minor imperfections, like rust or coatings, and is flexible enough to handle variations in the steel's composition and thickness.
Combining laser cutting with recycled steel is a powerful way for businesses to reduce their impact on the environment, save money, maintain high quality, and show their commitment to sustainability.
Nesting software figures out the best way to fit multiple parts onto a single sheet of metal, reducing leftover scraps and wasted material. It's a smart tool that considers the shape of each part, the size of the sheet, and even the direction of the metal grain.
By packing parts tightly together, nesting software makes the most of every inch of material. With less waste, more parts can be cut from a single sheet, speeding up production and making the entire process more efficient.
There are different types of nesting software, each with its own approach to solving the puzzle. Some are great for simple shapes, while others excel at complex designs. Advanced versions even consider things like avoiding collisions and optimizing leftover material.
Laser cutting's precision with thin-gauge steel offers another eco-friendly advantage. Using thinner materials means less material overall, which translates to less waste and a smaller environmental impact.
Remember the laser's narrow cut width and focused energy? These features make it perfect for working with thin materials, ensuring efficient cuts without damage. This maximizes material use, further minimizing waste.
Working with thinner materials new possibilities for lighter products. This is a game-changer in industries like automotive and aerospace, where reducing weight improves fuel efficiency and performance.
While laser cutting offers inherent advantages in sustainability, there are additional steps you can take to further minimize the environmental impact of the process:
The push for sustainability is on, and laser cutting is stepping up to the plate (pun intended). Its accuracy, energy savings, and ability to work with sustainable materials give it a clear edge over older methods.
Laser cutting means less waste, lower energy bills, and fewer harmful chemicals. That's good news for the planet and good news for your bottom line. It's a smarter way to work, and it's good for business.
If you need steel parts cut quickly, accurately, and with the environment in mind, our laser cutting services can help. Get in touch with Amber Steel to see how we can support your sustainability efforts while delivering top-notch results.
