Design guide for efficient laser cutting
Laser cutting offers unmatched precision, but the quality of the final result is decided at the drawing board. By keeping the following points in mind, we can produce more dimensionally accurate and more cost-effective parts.
1. Deliberate material selection
The speed and price of production depend heavily on choosing the right base material. It is worth choosing from the standard sheets we keep in stock.
- S235 steel: The most popular, economical structural steel.
- S355 steel: A higher-strength grade suited to increased loads.
- DC01 (cold-rolled): It has minimal internal stress, so it retains its accuracy even in thin sheets.
- 1.4301 stainless steel: A corrosion-resistant material that, for aesthetic purposes (e.g. visible surfaces), can also be ordered with protective film.
- Aluminium (AlMg3): Lightweight and easy to form, but its temper (H111–H24) determines how well it can be bent.
- Galvanised sheet: Excellent corrosion protection up to 3 mm thickness, without any subsequent surface treatment.
2. Geometry guidelines
Our software automatically handles certain details of the manufacturing process, so the designer does not have to make every technological correction.
- Kerf: The CAM software compensates for the material loss caused by the laser beam. On your drawings, specify the nominal (final) dimension.
- Inside corners: We recommend applying a minimal (0.5–1 mm) radius. This ensures a more even cut and reduces stress in the material.
3. Press-brake bending and accuracy
When designing the 2D flat pattern, the physical limits of the subsequent bending must be taken into account.
- Bend radius: Always design with a realistic radius appropriate to the material thickness. For this, use the manufacturer’s bending table.
- Modelling: For a precise flat pattern, in your design software (SolidWorks, Inventor) you should set the real bending parameters and K-factors.
4. Cost optimisation (nesting)
Material makes up a significant part of the production cost, so it is important to minimise scrap.
- Try to design shapes that can be nested into one another.
- Leave a technological gap of 4–8 mm between parts.
- More efficient material utilisation directly reduces the unit price.
Summary
The basis of successful production is close cooperation between the designer and the manufacturer. By observing the points above, we can achieve shorter lead times, lower costs and an excellent-quality end product.
Modern Sheet Metal Processing Technologies: The Foundations of Tomorrow’s Industry in 9 FieldsIf you have any questions about the above, or would like to have a part manufactured, get in touch with us!
