DEVELOPMENT TRENDS
Application and technology trends in laser materials processing
A look at some of the key developments currently taking place within the industrial laser sector
Industrial laser systems continue to advance at a rapid pace, with each year bringing new parameters, capabilities and applications. Here, we outline some of the key development trends we’ve observed over the past year, with laser technology having proven once again to be the ultimate tool for addressing the ever-evolving challenges of production.
Sheet metal cutting at 30kW and beyond Over the past couple of years, the number of companies offering flatbed sheet metal cutters with up to (and in some cases exceeding) 30kW of laser power has grown dramatically. At such powers, these systems are able to deliver thicker cuts, faster speeds, quicker piercing times, and in turn, lower cost per part. Such systems began emerging around 2019, when Chinese firm Bodor Laser unveiled its first 30kW system. However, the list of companies offering such power has now expanded to also include: Bystronic, Eagle Lasers, Cutlite Penta, Golden Laser, HG Laser, Morn Laser and Penta Laser, among others. Bodor Laser has since gone on to release a 40kW system. At such high powers, these systems can
reliably cut mild/stainless-steel, aluminium, brass and copper up to anywhere from 30 to 50mm, offering a more efficient and economical alternative to the plasma cutting technologies currently used to achieve thick
cuts. They are also expected to be used for achieving higher feed rates at the mid- plate range, from 10 to 20mm, where they offer dramatically higher cutting speed and edge quality. These high-powered flatbed cutters are targeted at firms producing equipment for agriculture, construction, and shipbuilding as well as metal service centres and job shops. For more information, see our cutting article on page 44.
Additive manufacturing for serial production Laser additive manufacturing (AM) is becoming established as a serial production tool in automotive and aerospace. This is due to ongoing developments dramatically ramping up its repeatability and productivity – such as optimised multi-laser scanning strategies and beam shaping, advancing metrology systems, better data handling and improvements along the digital process chain. An increasing number of system
providers are launching multi-laser systems that increase AM’s productivity to the point where it can now satisfy the throughput
requirements of serial production. The most extreme of these is SLM Solutions’ NXG XII 600E series, which utilises twelve 1kW lasers to offer build rates of up to 1,000cm3
/
hr. In addition, lasers with in-built beam shaping functionality, which enable rapid switching from Gaussian beam shapes to ring-mode shapes, are now being integrated into commercial AM systems. These different intensity distributions are able to induce more laser power into the parts without introducing defects, meaning the process speed can be increased. AM technology has developed to the point where giants such as BMW are now adopting it for serial production – with the firm, together with GKN Additive, having installed two fully autonomous serial AM production lines. The new lines will use laser powder bed fusion (LPBF) technology to produce around 50,000 components per year in common part production, as well as more than 10,000 individual and new parts. Using LPBF means certain tools are no longer required and new design possibilities can be realised – increasing flexibility and cost-effectiveness.
Blue/green laser development continues for copper processing Blue and green laser technologies continue to see power, brightness and beam quality improvements that enable them to better
“Laser additive manufacturing is becoming increasingly established as a serial production tool in automotive and aerospace”
A radio frequency quadrupole manufactured from electrolytic tough pitch (ETP) copper by Trumpf’s TruPrint 5000 system, which uses a green laser to deliver build rates of up to 100cm3/h
6 LASER SYSTEMS EUROPE THE 2023 GUIDE TO LASER SYSTEMS @LASERSYSTEMSMAG |
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