1. NATIONAL INSTITUTE OF FASHION TECHNOLOGY,
GANDHINAGAR
Ultrasonic, Laser, Plasma
Cutting Equipments
Under The Guidance of:-
Mr. Pavan Godiawala
Presented By:
NIVEDITA KUMARI
SUNIDHI KUMARI
RAVISH KHAN ( DFT-4)
SPME ASSIGNMENT -II
1
2. Cutting
2
Cutting – It is the process which cut out the pattern pieces
from specified fabric for making garments.
Types of Fabric cutting machines:
i. Manual, e.g. scissors, cutters.
ii. Semi-automatic, e.g. Round knife cutter, band
knife cutter, etc.
iii. Fully computerized, e.g. Laser, plasma, etc
3. Manual Cutting Machines
Scissors are normally used when cutting only single or double plies
Advantages:
1. Almost all types of cloths can be cut
2. Very cheap
Laser guided scissors Electric Scissors Decorative Edge scissors
Disadvantages:
1. Cannot be used for mass production
2. Cannot cut more than 2-3 piles of
fabrics
3. Low speed
4. Impossible to work continuously for
long hours
4. Semi-Automatic Cutting Machines
Advantages
• Comparatively cheap
• Production speed is very good
• Rough work can be easily done
by hands
Disadvantages
• Faulty knife could damage fabric
layer
• Knife required to change
• Weight of the motor creates
knife deflection which may be
Straight knife Round knife Band knife Notcher machine
5. Fully-Automatic Cutting Machines
Advantages
• Cutting defects are less
• Less labor cost
• Suitable for very large
scale of production
• No need of marker paper
Disadvantages
• Very expensive machines
• Very high on maintenance
• Not suitable for cutting multi
level fabric (water-jet, laser)
• Not suitable for synthetic
fabric(laser cutting)
Computerized
cutting machine Laser cutting machine Ultrasonic cutting Plasma cutting machin
7. What are ultrasonic waves?
7
Ultrasonic waves are an "inaudible sound," the
frequency of which generally exceeds 20 kHz. A
20-kHz frequency means that a certain medium
vibrates 20,000 times per second.
8. Elements required
8
1. GENERATER
2. A CONVERTER
Generator
Power: 75 / 150 /300 / 600 / 1,200 W
Frequency: 20 or 30 KHz
Supply: 110 / 220 v A/C
Converter
Aluminium outer body
Frequency: 20 or 30 kHz
Diameter: 42 / 50 / 76 / 82 mm
9. 9
3. A BOOSTER
4. A HORN
Boosters
Aluminium or titanium
Frequency: 20 or 30 KHz
Diameter: 42 / 76 /82
Sonotrodes/ horns
Wide range of sonotrodes for
various applications such as:
Textile cutting, Plastic welding and
Food cutting
11. Principle of Operation
11
The ultrasonic generator converts the power supply (100-
250 Volts, 50-60 Hz) into a 20 to 30 kHz, 800-1000 Volts
electrical signal. This signal is applied to piezo-electrical
ceramics (included in the converter) that will convert this
signal into mechanical oscillations.
These oscillations will be amplified by the booster and
converter, thus creating a hammer. The converter converts
electricity into high frequency mechanical vibration. The
active elements are usually piezo- electrics ceramics. The
booster (optional) serves as an amplitude transformer.
Amplitude magnification or reduction is achieved by certain
design features or the geometrical shape of the booster.
The horn, is the active part of the ultrasonic unit. It is in
contact with the fabric and acts as a hammer against the
counter-tool. This system will enable to melt the fiber within
12. 12
Piezoelectric crystals are small scale energy sources. Whenever
piezoelectric crystals are mechanically deformed or subject to vibration they
generate a small voltage, commonly know as piezoelectricity.
13. How cutting are done by the
ultrasonic cutter?
13
The ultrasonic cutter vibrates its blade with an amplitude of
10 - 70 µm in the longitudinal direction. The vibration is
microscopic, so it cannot be seen. The movement repeats
20,000 - 40,000 times per second (20 - 40 kHz). Because of
this movement, the ultrasonic cutter can easily cut resin,
rubber, nonwoven cloths, film, composite materials in which
various products are superposed, and food.
14. Features of cutters used in ultrasonic
cutting machines
14
High performance plotting and cutting
Over 25mm tool travel, handles uneven table surfaces
Optional vinyl sign cutting tool
Micro-stepper drive motors
Low cost consumable pens and blades
Self centring pen holder ensures quick changes and
accuracy with all marker types.
Runs from Macintosh or Windows PCs
HPGL compatible command language
Low maintenance
Optional remote joystick control.
Cutting widths up to 6.5m (256")
Cutting lengths up to 25m (82 feet)
15. 20kHz Titanium sonotrode
for replaceable cutting tips
Ultrasonic cutting assembly in mount Easy to replace screw on
tips
15
17. Specifications
17
SPEED – 0-18 m/min
MATERIALS CUT – 100 % synthetic or blends with up to 40 %
natural fibers.
MAXIMUM HEIGHT – upto 10 plies can be cut (mostly single
ply)
POWER REQUIRED –1400W
ULTRASONICALLY DRIVEN KNIFE BLADE
20-40 kHz VIBRATION FREQUENCY
1/20 MM MOVEMENT OF BLADE
CAUSES ONLY LOCALISED HEAT IN THE TEXTILE FIBRES.
IDEAL FOR MANY LOW-DENSITY FABRICS
ABSOLUTE POSITION ACCURACY IS REPEATABLE TO
0.008 inch.
LOW VACCUUM NEEDED
MADE UP OF ALUMMINIUM OR TITANIUM ALLOYS - never
becomes hot
18. Features
18
Their high-speed blades can cut man-made fabrics,
rubber, thermoplastic films, carbon and glass fibers
and Kevlar and Honeycomb materials with a high
degree of accuracy.
Due to high vibrations of Ultrasonic tip, the cut edges
are not only mechanically separated but also
thermally sealed.
Neat, clean & smooth edges can be obtained without
formation of beads on the cut edges.
No emission of cutting fumes in the cutting area so
reduces the expensive suction system.
19. 19
In the garment industry and other industries that work with
fabrics or high-tech composites, fraying or unraveling at
the cut can be a problem. Since ultrasonic cutters
generate just enough heat to seal the edges they cut,
they're popular with garment and airframe manufacturers.
Ultrasonic cutters also do a good job on fabrics or
composites that vary a lot in their thickness or weave
pattern, and they operate at frequencies from 20 to 40
kHz.
20. Materials
20
Materials may be 100 % synthetic or blends with up to 40
% natural fibers. Nonwovens, woven, stretch woven or
knit materials can be bonded and cut or slit.
the higher the synthetic content, the easier it is to cut and
seal with ultrasonic energy.
Some fabrics may be directional; that is, the fibers in one
direction have a different composition than the fibers in
the other direction. This may lead to different results
depending on the direction of the cut and seal.
21. Fabric cutting
21
Automated Ultrasonic Cutters are brilliantly effective
machines for cutting and edge-sealing synthetic fabric.
Offering production speeds better than conventional cutters,
Ultrasonic cutters can carry both ultrasonic and crush cutting
tools giving users the full choice of cutting and sealing
technologies to get the best results on any fabric.
Because more than one pattern can be nested and cut on a
vacuum table bed without moving the fabric, not only is
production speed increased, but fabric waste and mistakes are
reduced by a huge amount.
Tool pressures are computer controlled and set by the fabric
template in software so the right pressure is automatically
used for every job. This results in the best product quality but it
also means that tool life is optimised so that operating costs
22. 22
Ultrasonic Cutting Systems are designed to cut textiles
thermoplastic films, rubber woven and non-woven
fabrics. Ultrasonic Cutting Systems can be operated as
hand-held units or incorporated into automated
machinery
Solid, one-piece construction of horn blade virtually
eliminates breakage and energy loss
Minimal blade flexure yields straighter cuts without
having to support the blade
Available in 20, 30 or 40 kHz frequencies
Ideal for cutting composite aerospace materials such
carbon fiber, Nomex and various honeycombs.
24. Aeronaut's Ultra machines feature bayonet mount quick-
change tooling which means that even on the entry-level
Elektron B1 Ultra, one can swap from ultrasonic to crush cutting
in a matter of seconds.
24
26. The Elektron B2 Ultra is an Elektron B2 cutter fitted with an
ultrasonic tool and generator. It is present in Aeronaut
ultrasonic cutting machines.
26
27. Application of ultrasonic
27
The most application of ultrasonic onto fabric is
ultrasonic sewing (sealing),
ultrasonic fabric cutting and
ultrasonic lacing,
which applying ultrasonic a horn to trqansmit
ultrasonic energy onto fabric and a roller as
working tooling under pressure to process on
fabric to form sewing (sealing), cutting or lacing.
This procedure is widely appied in garment
industry, such as for underwear, bra, spot
wear, etc, and medical industry, such as face
mask, surgical cap, surgical gown, etc.
28. Ultrasonic cutting on fabric:
28
Ultrasonic fabric cutting uses cutting roller to work
combining with ultrasonic horn to cut fabric. The
cutting roller designed with cutting blade. It can cut
one fabric layer, two layers or more, limited by
ultrasonic specification’s ability. The cutting can be
linear or curve. After ultrasonic cutting, the cutting
edge is sealed, so the cutting edge is nor puffed,
while the sealed edge also keeps soft, not
discomforting skin. Ultrasonic cutting on textile is
widely used for the production of underwear and bra.
For the application in garment tailoring (used on
ultrasonic sewing machine), the cutting roller is
designed with a fabric pulling tooth for feed-in cloth. It
is necessary to put the specification roller design,
including the angle of cutting blade, depth of cutting
blade and pulling tooth, and the tolerance between
blade and pulling, which is depends on fabric
thickness and hardness.
30. Ultrasonic Sewing (Sealing):
30
Ultrasonic Sewing (also said as ultrasonic sealing) is
a kind of fabric process procedure base on ultrasonic
welding onto fabric. During ultrasonic sewing, a roller
designed with welding tooling rolling to work combing
with ultrasonic horn under pressure to weld two or
more fabric layers together. The welding pattern is
designed according to detail requirement, such as
patter specification, welding tooth’s height and
distance, which is defined by ultrasonic sewing quality
including the sewing strength, sewing out- look and
water-proof or air-tightness, etc, as well as fabric
specification (fabric thickness and material
composition). And the width of sewing will be limited
by fabric specification and ultrasonic capacity.
32. Ultrasonic Sewing (Sealing) and
Cutting:
32
Most of time, it request to cut away the extra
material after weld two or more fabric layers
together. To meet this need, it requests to design
both welding tooth and cutting blade onto the
roller to work combining together with ultrasonic
horn. During operation, the welding and cutting
work synchronously. This kind of procedures is
widely use onto both textile and nonwoven.
Besides the consideration mentioned in item 1) &
2), here it is necessary to mentioned that there is
height tolerance and between cutting blade and
welding tooth exits defined by fabric thickness.
Also, it need to consider the gap between welding
tooth and cutting blade, which depends on out-
look the mostly but not the only.
34. Ultrasonic lacing:
34
Ultrasonic lacing is mostly used for the decoration
for garment. Normally, because of the width of
lacing pattern, the roller is much wider than that
for fabric welding or cutting, which also request
ultrasonic in much higher power. During ultrasonic
lacing, the lacing roller will lace designed pattern
onto fabric under pressure together with
ultrasonic horn. Because normally it requests to
cut off the extra material, the roller pattern
requests to be designed as blade-like. The lacing
can be used onto single layers, double layers or
double layers with filling material between.
46. Advantages of ultrasonic cutting
machines
46
Clean separation of materials with sealed edges
Cutting and edge sealing in one process
Ultrasonic welding without overlap
Continuous cutting method using the rotary horn
Large variety in the cut / edge sealing design
Air and Watertight seams are producible
Accurate reproducibility of the welding results
Very low power consumption
Productivity increases of better than three times.
Reduced mistakes.
Reduced waste fabric.
47. Disadvantages of ultrasonic cutting
machine
47
Ultrasonic machines have relatively low MMR
(material removal rates)
The machining area and the depth of cut are quite
restricted.
It is necessary to clean the blade frequently to
avoid persistent residues that cause a change in
frequency of vibrations and damage the blade.
The ultrasonic technology is new and hence
presently expensive.
48. Hand held ultrasonic fabric cutter
48
Fabric types:
Awnings and interior blind fabrics
Screens
Performance fabrics
Any fusible fabric
Applications:
Handheld cutting operations :
Sun protection
Clothing
Ribbon
Bedding
50. 50
Characteristics:
Standard configuration for all type of products: flat
sonotrode and sharpened tools
Specific configuration for screen/product with plastic
to ease fabric penetration and avoid burning and
over-thickness: sharpened sonotrode with flat tools
Direct cutting : ultrasonic cutting and welding in one
single pass
Handheld cutting operations
Can be integrated on automatic cross cutting system
Technical specification:
Power : 300 W
Weight : 2.1 kg
Dimensions : 243 x 100 x 273 mm
51. Other Uses of Ultrasound in
Garment industry
51
Ultrasound in textile applications
- The effect of ultrasound on textile substrates and
polymers has started after the introduction of the
synthetic materials and their blends to the industry. These
include application in mechanical processes (weaving,
finishing and making up for cutting and welding woven,
nonwoven and knitted fabrics) and wet processes (sizing,
scouring bleaching, dyeing, etc).
- It deals with the application of ultrasound in the
mechanical processes of industrial as well as apparel
textiles. Ultrasonic equipment for cutting and welding has
gained increase acceptance in all sectors of the
52. 1. Ultrasonic Sewing: Tech
Breakthrough in Garment Industry
52
The garment industry is investing heavily into high
tech gadgets and equipment to create innovative
clothes which demand a look-see.
A new trend in this industry is the use of ultrasonic
‘sewing' machines which make it possible to stitch a
garment together without a trace of needles or
thread.
High frequency sound waves are used in this
process, to melt and bond edges of a fabric together.
The result is a clean and smooth seam that can lie
perfectly flush with the skin without causing any
53. ROTRAY ultrasonic sewing
53
ROTRAY ULTRASONIC
SEWING Machine HWR-
3010 makes use of
ultrasonic system with
30KHz frequency. It applies
a disk-like horn to work
together with roller for
sewing or cutting, machine
system transmits ultrasonic
energy at edge surface of
horn instead of at the
terminal surface. The
sewing/cutting roller ascends
& descends forced by a
pneumatic cylinder. This
machine model is suitable
for sewing & cutting on
material. The ultrasonic
sewing pattern width can be
56. At this point, the technology is
expensive and slower than normal
stitching. But this hasn't, deterred
big sports apparel brands such as
Nike from investing money into the
development of the process.
Ultrasonic sewing
machine
56
57. Ultrasonic sewing machine
57
HWR-2815 ultrasonic sewing
machine makes use of
ultrasonic system with 28KHz
frequency. Comparing to
20KHz ultrasonic, 28KHz is
inaudible to human, which is
health-friendly and
environment-friendly. The
sewing/cutting roller ascends
& descends driven by a
pneumatic cylinder. This
machine is suitable for
embossing, sewing and
cutting on material. The
ultrasonic sewing pattern
width can be max to 15mm
depends on fabric material.
Sewing pattern is changeable
by exchanging the
61. Ultrasonic Nonwoven Equipment-
Automatic Mask Production
61
This full automatic face mask
production line is designed by
HORNWELL ULTRASONIC,
used to produce flat face
mask. HORNWELL automatic
face makes machine realize
the automation from raw
nonwoven material to final
mask. It makes mask blanks
from fabric by blank mask
making machine, then collets
and conveys mask blanks by
conveying module and
distributes to each ear-loop
welding machine, after which
it has masks welded on ear-
loop by ear-loop welding
machines. The final masks
ware output from ear-loop
and put on to collection
convey belt help collection.
66. Advantages of ultrasonic sewing
66
Fast, economical, strong seals.
No consumables such as staples, adhesives, or clips.
Consistent results - from start-up to end of run.
No warm-up time, costly temperature maintenance, or
recovery time for an Ultrasonic Sewing Machine.
Single operation cut and seal with no raw edges.
Eliminates needles, threads, bobbins, and associated
color matching, inventory, winding, and trimming.
Non contaminating, eliminates toxic glue or solvents.
Edges are sealed with no stitch holes preventing
penetration of chemicals or blood borne pathogens.
67. 2. Ultrasonic-assisted wet processing
67
The use of ultrasound in textile wet processing offers many
potential advantages including energy savings, process
enhancement and reduced processing times.
Wet processing of textiles uses large quantities of water, and
electrical and thermal energy. Most of these processes involve
the use of chemicals for assisting, accelerating or retarding
their rates and are carried out at elevated temperatures to
transfer mass from processing liquid medium across the
surface of the textile material in a reasonable time. Scaling up
from lab scale trials to pilot plant trials have been difficult. In
order for ultrasound to provide its beneficial results during
dyeing, high intensities are required.
Ultrasound reduces processing time and energy consumption,
maintains or improves product quality, and reduces the use of
auxiliary chemicals. In essence, the use of ultrasound for
dyeing will use electricity to replace expensive thermal energy
and chemicals, which have to be treated in waste water.
69. LASER is a device that emits beams through a process of optical
amplification based on the stimulated emission of electromagnetic
radiation.
LASER- Acronym stands for “Light Amplification by Stimulated
Emission of Radiation”.
Spatial unity allows a laser to be focused to a spot and this enables
applications like laser cutting, engraving, marking etc.
Laser beam was invented by the physicist “Maiman”(for ruby
Experiment) in 1960.
70. Uses of Laser
In medicine- to break down gall
stones and kidney stones, to
remove clogging in human
arteries, weld broken tissues, hair
transplantation etc.
In Industry - to drill tiny holes in
hard materials, for cutting,
welding, engraving and machining.
In everyday life- to be used as
bar code reader, used in compact
discs, players and in digital
communications, etc.
In Garment Industry- Laser
washing, cutting ,engraving,
marking and growing in use for the
71. Laser Cutting
Laser cutting is a technology that uses a laser to cut
materials, and is typically used for industrial
manufacturing applications.
Laser cutting works by directing the output of a high
power laser, by computer, at the material to be cut.
In industrial cutting, the materials are either burns or
melt or vaporized away by a jet of gas leaving an
edge with a high quality surface finish.
Three main types of laser are-
1) Carbon dioxide laser- cutting, engraving.
2) Nd(neodymium)- Boring
3)ND-YAG(neodymium yttrium-aluminium-garnet)-
very high energy pulses, used in boring and
engraving
72. Properties of Laser…
Monochromaticity :
Concentrated in a narrow range
of wavelengths.
Directionality: Usually low in
divergence.
Laser can be transmitted,
reflected, refracted, absorbed
and has the capacity of
transmitting energy without loss
through the air.
High Irradiance: Power of
electromagnetic radiation per unit
area incident on a surface.
Coherence: All the emitted
photons bear a constant phase
73. Laser Mechanism
Laser works on the phenomenon of
Stimulated Emission.
Stimulated Emission- Atoms in an
excited state can be stimulated to
jump to a lower energy level when
they are struck by a photon of
incident light whose energy is the
same as the energy level difference
involved in the jump.
Electron thus emits a photon of
same wavelength.
In order to obtain the coherent light
from stimulated emission, two
conditions must be satisfied.
1.Inverted Population- more atoms
are in excited state compared to
ground level.
2.Metastable State- state where
electron remain longer than usual,
74. Absorption of energy
An atom absorbs energy in the form of heat, light,
or electricity. Electrons may move from a lower-
energy orbit to a higher-energy orbit.
76. Laser Development Process
1.) Pumping- In Laser, Lasing medium is “pumped”
to get atoms to an excited state(higher energy
levels).
2.) Stimulated Emission of atoms- This creates a
large collection of excited state atoms, thus
degree of population inversion increases.
3.) Reflection- The lasing process is enriched by
multiple reflection between mirrors.
4.) Production of Laser Beam- Laser beam exists,
the emitted energy comes in the form of photons
which has very specific wavelength(depends
upon the state of electron energy).
77. Types of Laser
Solid state lasers: Lasing
medium distributed in solid
matrix. Example- Ruby
Lasers.
Gas lasers: Helium and
Helium Neon(HeNe) are the
most common gases. CO2
laser is used for cutting hard
materials.
Dye laser(eg N2-
rhodamine)- different organic
compounds are used to
produce lasers.
Dye laser
Helium Neon(HeNe)
laser
78. Laser cutting machine parts
Laser cutting machine
heads and mirror mount
• Laser machine head
• Laser cutting head
• Mirror mounts
• Focal lens and reflecting mirror
• CO2 laser tube
• Nozzle size
• Gas inlet
• Pressure gauge
• Laser beam
• Attached Water coolant
• Software requirement- The default
Control Software is LaserCut 5.3, we
can choose LaserCut 5.3, AutoCAD
or Coreldraw.
79. Laser cutting Machine
A diagram of a laser
beam delivery system
in laser cutting
machine-:
1. CO2 laser resonator,
where the excitation of
carbon atoms produces
single wavelength light
emission.
2. Depolarising mirror
3 and 4. Telescope optics
5. beam benders
6. Focussing lens
7. Cutting head
8. Cutting nozzle
80. Laser Cutting Machine
Configuration
Generally, there are three different configurations of
industrial laser cutting machines :
Moving material
Hybrid
Flying optic system.
These refer to the way that the laser beam is moved over
the material to be cut.
The axes of motion are typically designated “x” and “y”
axis. If the cutting head may be controlled it is designated
as the “z” axis.
Speed of Laser cutting machine- 30-40m/min
Gas used in Laser Cutting machine- CO2 (wavelength-
10600nm)
81. Different types of laser machines
Laser cutting
o Fabric cutting
o Metal cutting
o Acrylic laser cutting
o Leather laser cutting
o Plastic laser cutting
o Wood laser cutting
Laser engraving machine
Laser marking machine- fibre marking,
CNC laser cutters- CNC cutting lasers and
engravers
CO2 laser cutting
82. Fabric and Metal Laser Cutting
Machines
They differ in the frequency of
CO2 laser requirement, a very high
wattages of laser is required to
penetrate through the metals.
Metals usually cut through by
melt and blow process. The
material is heated to melting point
then a gas jet blows the molten
material out of the kerf.
While fabric s are generally cut by
burning.
Provides easier holding and
reduced work piece in metals but in
fabric cutting , process become bit
labor consuming because each ply
Laser cutting of
metals
Laser cutting of fabrics.
83. Laser cutting of Fabric
There are three main types of lasers used for laser cutting:
the CO2 laser, the neodymium (Nd) laser and the neodymium
yttrium-aluminum-garnet (Nd-YAG) laser. The CO2 laser is
used when fabrics is to be cut. This particular process
involves firing a high-energy laser that cuts by melting,
burning or vaporizing material
.
Laser cutting materials includes various
woven and non-woven fabrics
organic materials such as silk, wool, cotton, leather, etc.
Artificial materials such as polyesters, nylons, acrylics,
neoprene, rubber.
Textiles suitable for laser cutting:
Aramid Cotton Felt Fleece Lace Polyester Silk Synthetic &
technical textiles
84. Various uses of laser cutting in
garment industry
FASHION – Specialty Design by cutting
patterns and creating special effects. The
graphics of different shapes and sizes can be
cut through computer design.
ENGRAVING can be done by laser machine
and engraving output graphics can be change
at any time only by designing in computer.
LABEL CUTTING – Laser cutting is used to
cut same size of label with no width/height
discrepancies.
STENCILS-Examples: Plastic letters,
Industrial Stencil Markers, House hold
decoration, Gaskets.
GARMENT DESIGNS- Cutting of garment
panels with intricate cut through designs
makes a quick and inexpensive item for
production samples.
86. Laser engraver
Etching onto fabrics such as Fleece and Denim is
becoming very fashionable and a point of difference
with manufactures.
87. Laser machines in garment industry
Laser carving machine: Laser engraver machines can
carve any complex graphics and the hollow sculpture and
blind slot sculpture without penetrating. Thus it can carve
a different color tone, different texture, levels and transition
color effects and various other magical patterns.
Laser carving machine can be applied in: leather shoes,
boots, fur clothing, trousers pieces, garment pieces, jeans
fabrics, labels, etc. sculpture all kinds of graphics.
Laser marking machine: Laser marking machine has a
high marking accuracy, speed, clearly marking, can mark
different wordage, symbols and pattern in hardware and
software.
Laser marking machine can be applied in: various kinds of
clothing, some buckle adorns, zipper, buckle, fastener, etc.
89. Silk Laser Cutting Technical Textile laser
cutting
Label Cutting by laser
Used in cutting of garment parts
90. Laser Technology In Denim
Washing
It is a computer controlled
process for denim fading.
This technique enables patterns
to be created such as lines
and/or dots, images, text or
even pictures.
It is water free fading of denim.
Being an automatic system,
chances of human error are
slim.
Also called spray painting in
denims.
91. JEANOLOGIA: Advanced Laser
Technology in Denim Finishes
Controlled process for denim fading.
These techniques enables patterns to be created such as lines
and/or dots, images, text or even pictures. It is water free fading of
denim.
Being an automatic system, chances of human error are slim. Also
called spray painting in denims.
This technique has relatively high cost.
The laser technology is the fastest growing technique presented by
many companies as a perfect replacement for traditional methods of
sandblasting, stone washing, burning, etc
JEANOLOGIA: New technology for jeans
finishing, faster and with less energetic
92. Advantages
Very high speed cutting
Laser cutting is a contact-less and consequently no bending or twisting
of textiles and fabrics during laser cutting.
No fraying of the fabric: lint-free & clean
The laser beam melts the material and the result are clean, perfectly
sealed edges. It is guaranteed that there will be no fraying of the end
products.
Laser engraving, laser marking and laser cutting all in one step
No tool wear - no loss of quality due to contact-free and force-free
processing
Simple production via a PC design program
Significant potential for cost saving for high quality raw
Extremely high accuracy of fit by full cutting gap compensation
Single ply laser cutters also make it possible to cut by color or shade
rather than by style.
Laser can work with stretch fabrics.
93. Disadvantages
Not suitable for cutting multi layer of fabric
Not suitable for synthetic fabric. Possibility of
burning
In the case of synthetic fibres: formation of a
fused seam
Sealed cutting edge preventing fraying of the
fabric
Sealed Edges of the fabric
94. Single Ply Cutting
Because it suffers from
limited depth of focus,
penetrating power is
less and other reason
includes, the heat
produced tends to seal
fabric edges, which is
disadvantage for cutting
multiple plies because
edges may fuse
together.
95. Garment Industrial Laser Cutting
and Engraving Machine (GLC-1680)
Basic Information-
Model NO.: GLC-1680
Automatic: Automatic
Type for Cutting
Machine:
Laser Cutting
Machine
Application: Garment Industry
Trademark: GLORYSTAR
HS Code: 84561000
Production
Capacity:
3500 Sets/Year
96. Product Description/Features
Model GLC-1680
Laser type Glass CO2 laser tube
Laser power
65w/70w/80w100w/12
0w/150w
Engraving area 1600× 800
Engraving speed 0-64m/min
Cutting spees 0-36m/min
Repeating lacating ± 0.05mm
Moving system CNC control system
Life Hours of Laser Tube Max. 10000 Hours
Cooling mode
Water-cooling and
protection system
Whole power ≤ 1250w
Working voltage 220± 10% 50Hz(60Hz)
Operating temperature 0~45º C
Prerating humidity 5%-95%
Controlling sofeware Glorystar laser software
Graphic format
supported
CAD BMP, JPG, PNG,
TIF, PCX, TAG, IOO, GIF,
PLT
Gross weight
170kg/230kg/270kg/32
0kg
Description
CO2 laser cutting and engraving
machines series are very popular in
the market around the world. They
have high stability and accuracy.
The quality and price ratio is very
high. The stepper motor and driving
system are imported from USA. The
equipments also inclusive of LCD,
PCB lamp motherboard, USB port,
water-cooling system, glass 70W
CO2 Laser tube, original straight-
line guide rail from Japan
Applications & Materials
Engraving/ cutting of fabric and
leather in garment, embroidery, toy,
handbag, glove (optional
honeycomb baseboard)
97. Laser Marking System Speed Marker
700
The SpeedMarker 700:
reliable all round workstation
103. Shanghai Large Working Area Laser
Cutting Bed (High Speed)
Features:
Luxury design
High accuracy ball screw
1:4 wheel speed ratio to keep high quality cutting effect
3 phase motors works at higher speed than common
motors
Switch design in conformity with CE standard
Control chip allows the machine work fast. stably, with
high anti-interference capability
Self-developed high-efficiency laser power supply
Applications:
mainly used in large area materials cutting and pieces
cutting
suitable materials: fabric, leather, paper, wood, organic
glass ,rubber, plastic and synthetic materials
Meet the demand of professional use’s requirement of
cutting and engraving on large size, garment, fabric,
leather, furniture, packing. Advertising, decoration,
105. Factors that should be considered
before buying laser cutting machine.
Laser power
Laser type
Cutting speed
Movement of laser (x,y,z)
Maximum width that can be cut.
Laser cutting depth
Materials that can be cut.
Cooling mode
Working area/ Processing area
Working voltage
Life hours of laser tube.
Power supply
Slope Engraving
Resetting Positioning Accuracy
Graphic format supported and controlling software, etc.
106. Major manufacturers in laser
technology
Mitsubishi Electric
Gerber
Jinan morn technology limited
Lectra systems
Embrace laser
Glorystar
Sahajanand laser technology limited
GBO lasers
HE lasers.
107. Limitations and hazards related to Laser
Cutting
Lasers are used for single ply cutting only.
Widespread use of laser system is still
limited because of the high cost of
investment in equipment.
Most materials have a by product of debris,
odor, or both.
Some of the fumes can be irritating to the
lungs, nose, or eyes making for an
uncomfortable working environment.
Some of the out-gassing can actually be
toxic to humans.
Certain materials create debris during
processing that can be damaging to the
mechanics of system.
Unvented debris and fumes will adversely
affect the optical components within the
system.
There are state-wide, regional, and country-
specific environmental laws that require the
capture of fumes and debris caused by
many types of processes, including lasing.
108. Present Figures of laser products
made and Its Top manufacturers
https://editd.com/blog/2012/05/the-laser-display-cutting-edge-of-a-trend/
109. Latest development and future of
laser machines
Lectra Systems, one of the leaders in
developing laser technology, has added
robotic spreading and flaws detection to
the cutting operation.
A camera extended on an arm above
the spread, monitors the fabric for flaws
and reads the width of the fabric.
When a flaw is detected , the operator
can reposition the pattern pieces to
avoid the defect, which ensures a
defect free garment or a perfectly
matched plaid or patterns.
Robotic laser processing on UHSS
components has made inroads in
recent years, as has five-axis laser
cutting of these critical components, as
automakers seek more efficient
methods of handling
Three-dimension laser scanning
technology is a tool that is germane to
the exploration of wide variety of
research areas encompassing
disciplines as diverse as science,
111. Plasma
Plasma can be defined as a
partially or wholly ionized gas
with a roughly equal number
of positively and negatively
charged particles. Some
scientists have dubbed
plasma the “fourth state of
matter” because while plasma
is neither gas nor liquid, its
properties are similar to those
of both gases and liquids.
114. Plasma Cutting
Plasma cutting is a process that is used to cut
steel and other metals using a plasma torch. In
this process, an inert gas (in some cases,
compressed air) is blown at high speed out of a
nozzle; at the same time an electrical arc is
formed through that gas from the nozzle to the
surface being cut, turning some of that gas to
plasma.
Computer-controlled torches can pierce and cut
steel up to 40 mm thick.
115. The plasma is sufficiently hot to melt the metal
being cut and moves sufficiently fast to blow
molten metal away from the cut. Plasma is an
effective means of cutting thin and thick materials
alike.
Plasma cutting is used to cut
ferrous (stainless steel, cast iron, pig steel, etc.)
non-ferrous metal (aluminum, copper, tool steel,
die steel, lead, nickel, tin, titanium and zinc, and
alloys such as brass, etc).
117. Plasma cutters work by sending a pressurized
gas (nitrogen, argon, or oxygen) through a small
channel. In the middle of this channel, a
negatively charged electrode exists. When
applying power to the negative electrode, and
connecting the tip of the nozzle to the metal, the
bond creates a circuit.
This will generate a powerful spark, created
through the electrode and metal bond. As the gas
passes through the channel, the spark boosts the
temperature of the gas until it reaches the fourth
state of matter called plasma. This reaction
creates a stream of plasma, approximately
118.
119. Pros
It requires no preheating so that the torch can begin
its cutting immediately, which saves time and is more
convenient.
Cuts any type of electrically conductive metals
including aluminium, copper, brass and stainless
steel, that is 6” thick.
Its speed is up to 500 IPM(inches per minute) and it is
one of the best versatile welders.
Produces a small and more precise kerf (width of the
cut)— great when precision matters
With its high precision components, it eliminates the
cost of some secondary operations.
Lower price and operating costs.
120. Has a smaller heat affected zone which prevents the
area around the cut from warping and minimizes paint
damage
Provides gouging and piercing capabilities
It is safe and offers a quality system that draw smoke
away from the operator
It has adjustable post flow cooling and over current
warning facility.
Cons :
It requires frequent replacement of some spare parts
if it is not used properly.
Limited to cutting only 160mm. thick material.
122. Power source
The power source required for the plasma arc
process must have a drooping characteristic and
a high voltage. Although the operating voltage to
sustain the plasma is typically 50 to 60V, the open
circuit voltage needed to initiate the arc can be up
to 400V DC.
On initiation, the pilot arc is formed within the
body of the torch between the electrode and the
nozzle. For cutting, the arc must be transferred to
the workpiece in the so-called 'transferred' arc
mode. The electrode has a negative polarity and
the workpiece a positive polarity so that the
majority of the arc energy (approximately two
123. Gas composition
In the conventional system using a tungsten
electrode, the plasma is inert, formed using either
argon, argon-H2 or nitrogen. However, as
described in Process variants, oxidising gases,
such as air or oxygen, can be used but the
electrode must be copper with hafnium.
The plasma gas flow is critical and must be set
according to the current level and the nozzle bore
diameter. If the gas flow is too low for the current
level, or the current level too high for the nozzle
bore diameter, the arc will break down forming
two arcs in series, electrode to nozzle and nozzle
to workpiece. The effect of 'double arcing' is
usually catastrophic with the nozzle melting.
124. Gas Regulators
Gas regulators comprise of regulators that
allows for handling CO2, Argon and Oxygen
welding support.
These regulators are designed for assuring
trouble-free services and ensure complete
stability in gas flow, smooth gas pressure
regulation as well as in maintaining precise
control of pressures.
Features:
Highly functional range of Gas Regulators
Suitable for CO2, Argon, Oxygen welding
applications
Allow precise control over gas flow even at
low pressures
Gauge provided for easy dial reading
125. Nozzle:
The nozzle's design features are crucial to obtaining
optimal cut quality.
The nozzle is designed so that the orifice is slightly
larger than the vortex of ionized gas being focused.
This allows the nozzle to contain and focus the vortex
of plasma without being adversely affected by it.
Cut quality suffers when either the exterior or interior of
the nozzle orifice becomes damaged.
Internal nozzle damage is caused by a blown
electrode, piloting problems and gas flow problems, or
current settings that are either too high or too low
(overpowering and underpowering of the nozzle).
External nozzle damage may be caused by excess
metal spatter on the nozzle that may occur if the torch
cuts too close to the plate or pierces thick metal.
Nozzle Shield: The shield protects the nozzle from
being damaged during the cutting process.
126. Cut quality
Factors to consider in evaluating the quality of a cut
include:
surface smoothness,
kerf width,
kerf angle(normally 5 to 6 degrees),
dross adherence and sharpness of the top edge,
the type of material being cut,
the equipment being used and
the cutting conditions.
The process variants, Figs. a to e, have principally been
designed to improve cut quality and arc stability,
reduce the noise and fume or to increase cutting
speed.
127. Dual Gas
The process operates basically in the same manner as
the conventional system but a secondary gas shield is
introduced around the nozzle, Fig. a. The beneficial
effects of the secondary gas are increased arc
constriction and more effective 'blowing away' of the
dross. The plasma forming gas is normally argon,
argon-H2 or nitrogen and the secondary gas is selected
according to the metal being cut.
Steel
air, oxygen, nitrogen
Stainless steel
nitrogen, argon-H2, CO2
Aluminum
argon-H2, nitrogen / CO2
The advantages compared with conventional plasma
are:
Reduced risk of 'double arcing‘
Higher cutting speeds
Reduction in top edge rounding
Fig. a
128. Water Injection
Nitrogen is normally used as the
plasma gas. Water is injected
radially into the plasma arc, Fig. b,
to induce a greater degree of
constriction. The temperature is
also considerably increased, to as
high as 30,000°C.
The advantages compared with
conventional plasma are:
Improvement in cut quality and
squareness of cut
Increased cutting speeds
Less risk of 'double arcing‘
Reduction in nozzle erosion Fig. b
129. Water Shroud
The plasma can be operated either with a water
shroud, Fig. c, or even with the workpiece submerged
some 50 to 75mm below the surface of the water.
Compared with conventional plasma, the water acts as
a barrier to provide the following advantages:
Fume reduction
Reduction in noise levels
Improved nozzle life
In a typical example of noise levels at high current
levels of 115dB for conventional plasma, a water
shroud was effective in reducing the noise level to
about 96dB and cutting under water down to 52 to
85dB.
As the water shroud does not increase the degree of
constriction, squareness of the cut edge and the
cutting speed are not noticeably improved.
Fig. c
130. Air Plasma
The inert or unreactive plasma forming gas
(argon or nitrogen) can be replaced with air
but this requires a special electrode of
hafnium or zirconium mounted in a copper
holder, Fig. 2d. The air can also replace water
for cooling the torch.
The advantage of an air plasma torch is that it
uses air instead of expensive gases.
It should be noted that although the electrode
and nozzle are the only consumables,
hafnium tipped electrodes can be expensive
compared with tungsten electrodes.
Fig. d
131. High Tolerance Plasma
In an attempt to improve cut quality and to compete with the
superior cut quality of laser systems, High Tolerance Plasma
Arc cutting (HTPAC) systems are available which operate with
a highly constricted plasma. Focusing of the plasma is
effected by forcing the oxygen generated plasma to swirl as it
enters the plasma orifice and a secondary flow of gas is
injected downstream of the plasma nozzle, Fig. e. Some
systems have a separate magnetic field surrounding the arc.
This stabilises the plasma jet by maintaining the rotation
induced by the swirling gas.
The advantages of HTPAC systems are:
Cut quality lies between a conventional plasma arc cut and
laser beam cut
Narrow kerf width
Less distortion due to smaller heat affected zone
The main disadvantages are that the maximum thickness is
limited to about 6mm and the cutting speed is generally lower
Fig. e
132. Cut Quality Problem : Dross And
Its Removal
Dross is re-solidified oxidized molten metal that is not
fully ejected from the kerf during cutting. It is the most
common cut quality problem of plasma cutting.
Dross may form as a thick bubbly accumulation along
the bottom edge of the plate (low speed dross), a small
hard bead of uncut material (high speed dross) or a light
coating along the top surface of the plate (top spatter).
Dross formation is dependent on many process
variables like torch travel speed, standoff distance,
amperage, voltage and consumable condition and
material variables such as thickness and type of
material, grade, chemical composition, surface
condition, flatness, and even temperature changes in
the material as it is cut.
However, the three most critical variables to consider in
dross formation are cutting speed, amperage, and
standoff distance.
134. Plasma Cutting In Textiles
Using this system, fabric are cut by a thin through
the nozzle which is made by Argon gas.
One or more fabric plies can be cut .
Most useful for cutting single ply of fabric.
Fabrics are cut by placing in a table, the surface
(85%) of which must be place in a perforated
blanked place.
135. Advantages
Automatic torch height control system
Automatic oxy-fuel gas control system
Automatic torch explosion system
Pneumatic band clamping
Standard auto-nesting package
Easily networked
Synthetic fiber not cut
Higher number of fabric lay is not cut
Need higher skill operator
Costly
Disadvantages
136. Other Applications of Plasma
Technology in Textile
Desizing of cotton fabrics.
Hydrophobic enhancement of water and oil-repellent
textiles
Anti-felting/shrink-resistance of woolen fabrics.
Hydrophilic enhancement for improving wetting and
dyeing.
Hydrophilic enhancement for improving adhesive
bonding
Removing the surface hairiness in yarn.
Scouring of cotton, viscose, polyester and nylon
fabrics.
Anti-bacterial fabrics by deposition of silver particles
in the presence of plasma.
Room-temperature sterilization of medical textiles.
138. Desizing Of Fabric Using Plasma
Plasma technology can be used to remove PVA sizing
material from cotton fibers.
In conventional desizing process we use chemicals and
hot water to remove size. In desizing with plasma
technology either O2/He plasma or Air/He plasma is used.
Firstly the treatment breaks down the chains of PVA
making them smaller and more soluble.
X-ray photoelectron microscopy results reveal that plasma
treatment introduces oxygen and nitrogen groups on the
surface of PVA which owing to greater polarity increase the
solubility of PVA.
Of the two gas mixtures that were studied, the results also
indicate that O2/He plasma has a greater effect on PVA
surface chemical changes than Air/He plasma.
139. PLASMA TREATMENT OF WOOL TO
ACHIEVE SHRINK-RESISTANCE
The morphology of wool is highly complex; this is
not confined to the fiber stem but extends to the
surface as well.
Cuticle cells are overlapping each other to create
a directional frictional coefficient.
Moreover, the very surface is highly hydrophobic.
As a consequence, in aqueous medium, because
of the hydrophobic effect, fibers aggregate and,
under mechanical action, exclusively move to
their root end.
This is the reason for felting and shrinkage.
Plasma treatment of wool has a two-fold effect on
the surface.
First, the hydrophobic lipid layer on the very
surface is oxidized and partially removed; this
applies both to the adhering external lipids as well
140. Amount of covalently bound surface lipids in dependence on the
treatment time in barrier discharges detected after isolation by
transesterfication and subsequent weight determination.
141.
142. Dyeing Of Fabric Using Plasma
The dye exhaustion rate of plasma treated wool
can increase by nearly 50%.
It has been shown that O2 plasma treatment
increases the wetability of wool fabric thus
leading to a dramatic increase in its wicking
properties.
Also the disulphide linkages in the exocuticle
layer oxidize to form sulphonate groups (which
act as active sites for reactive dyes) also add to
the wetability .
The etching of the hydrophobic epicuticle and
increase in surface area also contributes towards
the improvement in the ability of the fibers to wet
more easily.
143. The graph below shows that plasma treated wool can achieve 90% exhaustion in
30 minutes as compared to 60 minutes for untreated samples.
When wool is dyed with reactive dyes maximum exhaustion is achieved A
possible explanation to this behavior of reactive dyes is due to the increase in
sulphonate groups on the fiber surfaces.
144. PLASMA STERLISATION FINISH
ON COTTON
Low temperature plasma sterilization is a green technique
and is regarded as one of the most promising sterilization
techniques. The low temperature oxygen plasma can
sterilize cotton fabrics contaminated with microorganisms.
There are three basic mechanisms involved in the plasma
inactivation of microorganisms:
(A) Direct destruction by UV irradiation of the genetic
material of microorganisms;
(B) Erosion of the microorganisms, atom by atom, through
intrinsic photo desorption by UV irradiation to form volatile
compounds combining atoms intrinsic to the
microorganisms;
(C) Erosion of the microorganisms, atom by atom, through
etching to form volatile compounds as a result of slow
combustion of oxygen atoms or radicals emanating from
the plasma .
145. The UV and activated free
radicals generated during
plasma treatment weaken the
cell wall of the microorganisms
by reacting with the
hydrocarbon bonds, and cause
disruption of unsaturated
bonds, particularly the purine
and pyrimidine components of
the nucleoproteins.
The oxygen plasma treatment
completely sterilizes the cotton
fabrics contaminated with
bacteria.
In addition, the plasma
147. Corona treatment of air and oxygen plasma
Frictional values
Dye uptake wicking rate
Breaking strength
Plasma containing phosphorous and halogen
compounds
Flame retardancy
Air-oxygen-helium atmospheric plasma treatment
Removal PVA
Increased PDR by cold water washing
Non-polymerisable(oxygen) plasma
Scouring (improved by 50%)
148. PLASMA TREATMENT OF
WOOL
Air or oxygen-helium plasma treatment (low or
atmospheric pressure)
wettability
Strength
Shrinkage resistance
Anti-felting
Dye-ability
Plasma treatment followed by silicone treatment
Dimensional stability
Wrinkle resistance
Plasma treatment followed by biopolymer chitosan
treatment
Shrink resistance
149. PLASMA TREATMENT OF SILK
Tetramethyl disiloxane, oxygen plasma
Dye absorption
Flame resistance
Wrinkle recovery
Low temperature plasma treatment
Bio-compatibility
Fluorinating plasma treatment
Water repellancy
PLASMA TREATMENT OF POLYESTER
Radio frequency air plasma treatment
Reduced surface resistance
Increased moisture content
150. APPLICATION OF PLASMA
PARTICLES ON FIBER
Enhance mechanical properties Softening of cotton and
other cellulose-based polymers, with a treatment by
oxygen plasma. Reduced felting of wool with treatment by
oxygen plasma. Top resistance in wool, cotton, silk fabrics
with the following treatment: dipping in DMSO and
subsequently N2-plasma. .
Wetting Improvement of surface wetting in synthetic
polymers (PA, PE, PP, PET PTFE) with treatment in O2-,
air-, NH3-plasma. Hydrophilic treatment serves also as
dirt-repellent and antistatic finish. Hydrophobic finishing of
cotton, cotton/PET, with treatment with siloxan- or per
fluorocarbon- plasma. Oleo phobic finish for
cotton/polyester, by means of grafting of perfluoroacrylat.
Dyeing and printing. Improvement of capillarity in wool and
cotton, with treatment in oxygen plasma. Improved dyeing
polyester with SiCl4-plasma and for polyamide with Ar-
plasma.
151. Composites and Laminates. Good adhesion between
layers in laminates depends upon the surface
characteristics of fibers in layers and the interactions
taking place at the interface. A prerequisite condition
of good adhesion remains the surface energy of
fibers, which can be modified with plasma treatments.
Applications in Membrane and Environmental
Technology.
Gas separation to obtain oxygen enrichment.
Solution-Diffusion Membranes to obtain alcohol
enrichment.
Ultra filtration membranes to improve selectivity.
Functionalized membranes such as affinity
152. Potential hazards
The potential hazards involved with the plasma
cutting process include:
high voltages
noise
temperatures
flammable materials
fumes
ultraviolet radiation
molten metal
153. Safety features
A Nozzle-in-Place safety sensor: If the output is
turned on, the operator will be exposed to 300
VDC, a very unsafe condition. With such a
feature, the plasma cutter will not start an arc
unless the nozzle is in place.
A pre-flow sequence: This feature provides an
advanced warning to the use before the arc
initiates.
155. Safety Tips
Plasma cutter Arc Rays Plasma cutter arc rays produce
intense visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin so proper welding clothing,
Guantlet gloves,safety shoes or insulated boots and hat
should be worn.
Flame-retardant clothing to cover all exposed areas.
Cuffless trousers to prevent entry of sparks and slag.
Keep your body and clothing dry.
Shaded eye protection, welding helmets with dark lenses
should be worn or as specified by the manufacturer should
be followed. Typically a darkness shade of #7 to #9 is
acceptable.
Before cutting, inspect the shield cup, tip and electrode
and do not operate the unit without the tip or electrode in
place.
Hitting the torch on a hard surface to remove spatter can
damage the torch and stop proper operation.
156. In addition, avoid constant starting and
restarting of the plasma arc to lengthen
consumable life
Plasma cutter output voltages are generally
100-200 volts. Precautionary Measures. Do
not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in
place on the workbench with the work cable
attached during the cutting process and do
not move the work clamp.
Insulate yourself from work and ground using
dry insulating mats or covers big enough to
prevent any physical contact with the work or
ground.
Do not attach work cable to the piece that will
fall away when the cut is complete.
Remove combustibles, such as a butane
lighter or matches, from your pockets before
cutting.
157.
158. Comparison between Plasma Cutting
Machine and Laser Cutting Machine:
The tables that follow contain a comparison of
metal cutting using the CO2 laser cutting process
and plasma cutting process in industrial material
processing.
Fundamental process differences
Typical process applications and uses
Initial investment and average operating costs
Precision of process
Safety considerations and operating environment
159. Fundamental Process Differences
Subject CO2 Laser Plasma Cutting
Method of imparting energy Light 10.6 µm (far infrared
range)
Gas transmitter
Source of energy Gas laser DC power supply
How energy is transmitted Beam guided by mirrors
(flying optics); fiber-
transmission not
feasible for CO2 laser
Electrically charged gas
How cut material is
expelled
Gas jet, plus additional gas
expels material
Gas jet
Distance between nozzle
and material and maximum
permissable tolerance
Approximately 0.2" ±
0.004", distance sensor,
regulation and Z-axis
necessary
0.010" to 0.02"
Physical machine set-up Laser source always
located inside machine
Working area, shop air and
plasma torch
Range of table sizes 8' x 4' to 20' x 6.5' 8' x 4' to 20' x 6.5'
Typical beam output at the
workpiece
1500 to 2600 Watts Not applicable to this
process
160. Typical Process Applications And Uses
Subject CO2 Laser Plasma Cutting
Typical process uses Cutting, drilling, engraving,
ablation, structuring, welding
Cutting
3D material cutting Difficult due to rigid beam guidance
and the regulation of distance
Not applicable to this process
Materials able to be cut by the
process
All metals (excluding highly
reflective metals), all plastics,
glass, and wood can be cut
All metals can be cut
Material combinations Materials with different melting
points can barely be cut
Possible materials with different
melting points
Sandwich structures with
cavities
This is not possible with a CO2
laser
Not possible for this process
Cutting materials with limited or
impaired access
Rarely possible due to small
distance and the large laser cutting
head
Rarely possible due to small
distance and the large torch head
Properties of the cut material
which influence processing
Absorption characteristics of
material at 10.6 µm
Material hardness is a key factor
Material thickness at which
cutting or processing is
economical
~0.12" to 0.4" depending on
material
~0.12" to 0.4"
Common applications for this
process
Cutting of flat sheet steel of
medium thickness for sheet metal
processing
Cutting of flat sheet and plate of
greater thickness
161. Initial Investment And Average
Operating Costs
Subject CO2 Laser Plasma Cutting
Initial capital investment
required
$300,000 with a 20 kW
pump, and a 6.5' x 4'
table
$120,000+
Parts that will wear out Protective glass, gas
nozzles, plus both dust
and the particle filters
The cutting nozzles and
electrodes
Average energy
consumption of
complete cutting system
Assume a 1500 Watt
CO2 laser:
Electrical power use:
24-40 kW
Laser gas (CO2, N2,
He):
2-16 l/h
Cutting gas (O2, N2):
500-2000 l/h
300 amp Plasma
Electrical power use:
55kW
162. Precision Of Process
Subject CO2 Laser Plasma Cutting
Minimum size of the
cutting slit (kerf width)
0.006", depending on
cutting speed
0.002"
Cut surface appearance Cut surface will show a
striated structure
Cut surface will show a
striated structure
Degree of cut edges to
completely parallel
Good; occasionally will
demonstrate conical
edges
Fair, will demonstrate
non-parallel cut edges
with some frequency
Processing tolerance Approximately 0.002" Approximately 0.02"
Degree of burring on the
cut
Only partial burring
occurs
Only partial burring
occurs
Thermal stress of
material
Deformation, tempering
and structural changes
may occur in the
material
Deformation, tempering
and structural changes
may occur in the
material
Forces acting on
material in direction of
gas or water jet during
processing
Gas pressure poses
problems with thin
workpieces, distance
cannot be maintained
Gas pressure poses
problems with thin
workpieces, distance
cannot be maintained
163. Safety Considerations And
Operating Environment
Subject CO2 Laser Plasma Cutting
Personal safety
equipment
requirements
Laser protection safety
glasses are not
absolutely necessary
Protective safety
glasses
Production of smoke
and dust during
processing
Does occur; plastics
and some metal alloys
may produce toxic
gases
Does occur; plastics
and some metal alloys
may produce toxic
gases
Noise pollution and
danger
Very low Medium
Machine cleaning
requirements due to
process mess
Low clean up Medium clean up
Cutting waste produced
by the process
Cutting waste is mainly in
the form of dust requiring
vacuum extraction and
filtering
Cutting waste is mainly in
the form of dust requiring
vacuum extraction and
filtering
