Speed Meets Precision: Cutting Systems Increase Output and Cut Costs
No matter the cutting system, be it fiber laser, plasma, or waterjet system solutions, the key to success is a machine’s delivery of fast and precise cuts on a range of sheet metal materials, versatility in product features, a compact and reduced footprint, and the ability to seamlessly integrate automation systems.
New Tube Laser Solution
BLM GROUP USA’s (Novi, MI) introduces the LT14 Fiber Tube Laser, which processes tube diameters up to 14” and lengths up to 54’ with greater speed, precision and efficiency. It delivers the benefits of advanced fiber laser technology — faster cutting on thin-walled tubes, improved cut quality on thicker and scaled sections, and lower overall operating costs. It is well suited to manufacturers in structural steel, energy and power generation, off-highway and agricultural equipment, transportation, shipbuilding, and heavy equipment industries.
Enhanced capabilities include automatic beam shaping technology for cutting across diverse materials and thicknesses, advanced nesting software to maximize yield, and automated handling of tubes up to 54”. A short-parts conveyor allows operators to automatically unload parts up to 10.5” without requiring a scrap pit or micro-tabbing parts, which eliminates secondary processing steps. The LT14 Fiber is also equipped with three heavy-duty spindles that automatically adjust clamping force to match the material.
Updated Version of Plasma Machine
Machitech Automation (Saint-Marc-des-Carrieres, Québec, Canada) offers a new version of its Titanium Cut plasma machine for cutting, drilling, tapping and machining of heavy-duty steel plates. Specially designed for steel service centers, shipbuilders, and all types of structural steel fabricators; the Titanium Cut plasma machine can tap and machine plates up to 2” and drill holes up to 4” with its 50 hp spindle. Cutting capabilities include speeds from 0-to-500 IPM, traverse speeds up to 1,000 IPM, repeatability to 0.002”, and positioning accuracy to 0.004”. The Titanium Cut features the Machitech NX4 CNC Controller and Hypertherm Pronest CAD/CAM Software. It incorporates Hypertherm’s XPR460 high performance plasma system for maximum productivity in X-Y axis cutting, beveling and robotic cutting operations. With a versatile 460-amp rated system, the Titanium Cut plasma machine combines fast cutting speeds, rapid process cycling, and quick changeovers reliably. Other plasma systems are available.
Other Titanium Cut standard features include a customizable bridge and rail system, a table size range from 8’-by-20’ up to 30’-by-300’, a 40’-by-20’ reinforced fabricated gantry, a patented inverted rail system, industrial servomotors, Bosch linear ways on the rails and gantry, a rotary tool changer with 16 stations, and mist coolant through tools. Options include additional plasma cutting stations, a 5-axis full contour bevel head, a cut and clean slag removal system, marking systems, up to 10 oxyfuel torches, chip and coolant extraction system, a dust collector, flood coolant capabilities, and other nesting software.
Ultra-High-Speed and Precision-driven Processing
Experience unmatched fiber laser cutting performance with AMADA AMERICA, INC.’s (Buena Park, CA) 26 kW REGIUS 3015 AJe, featuring the world’s fastest three-axis linear drive system. Achieve exceptional point-to-point positioning speeds of 13,386” per minute with unparalleled accuracy. This cutting-edge system sets a new benchmark in laser cutting technology.
Enhanced by AMADA’s Laser Integration System, the REGIUS 3015 AJe ensures peak productivity through autonomous innovations, including automatic inspection, defect prevention, and seamless error correction. Advanced features such as the i-Nozzle Checker, i-Optics Sensor, and Variable Beam Control Technology optimize cutting performance and system calibration without manual intervention. These technologies minimize downtime and deliver flawless cuts across a wide range of materials and thicknesses. A user-friendly interface, a large touch screen, and one-touch operations simplify tasks. The optional i-Camera Assisted System enhances remnant cutting by displaying selected remnants on
the control screen, allowing for easy positioning and manipulation before cutting.
The REGIUS 3015 AJe seamlessly combines speed, precision, and innovation, redefining productivity and edge quality in laser cutting while ensuring unprecedented ease of use.
Total Plate Processing Solution
Tecoi USA (Longview, TX) is redefining large-format plate processing through the seamless integration of thermal cutting, mechanical machining, and automated material handling. Tecoi’s total plate processing solution starts with either large format plasma and oxyfuel cutting or large format laser cutting.
Engineered for heavy-duty thermal cutting applications, Tecoi’s THOR combines plasma and oxyfuel cutting with advanced mechanical operations. It can be configured with one or two drill heads, capable of drilling holes up to 5.5” in diameter. THOR supports up to two plasma systems and 10 oxyfuel torches, offering beveling capabilities for both plasma and oxyfuel processes. THOR incorporates mechanical machining features such as milling, drilling, tapping, countersinking, and marking, enabling multi-process part manufacturing in a single setup.
Tecoi’s LS Series combines advanced laser cutting with optional high-performance mechanical drilling. Also designed for large format plate processing, the LS Series features TwinDisk, a proprietary technology that allows full laser power to be directed to a single cutting head for maximum intensity or split between two heads for simultaneous dual-head cutting. It also incorporates Dual Fiber Process, utilizing two fiber lasers per head to deliver the optimal optical configuration for both thin and thick materials. In addition to laser capabilities, the system offers the flexibility of configuring one or two drilling heads, each equipped with up to six tools. The LS Series supports drilling up to 7/8” and M12 tapping, with ultra-fast tool changes in as little as 0.8 seconds.
Tecoi’s total integrated solution then includes StockTec, its automated material handling system capable of processing plates up to 10′-x-50′. StockTec can be configured with one or multiple vertical storage towers. Complementing StockTec is Loadtec, a dedicated crane system engineered to automatically load raw plates and unload nested parts. For post-cutting operations, Robotec provides a fully automated robotic sorting system that identifies, picks and organizes parts.
Waterjets Support Unique Cutting
Flex Machine Tools (Wapakoneta, OH) can configure a FlexJet waterjet system to meet unique cutting requirements. Customers can choose the pump, cutting head and machine size that is right for the application. FlexJet waterjet systems offer industry leading speed and rapid positioning, with head options ranging from conventional, 5-axis and tilter to multi-head setups. The multiple cutting head solutions provide increased efficiency by multiple heads cutting parts at one time, reducing overall cutting time and cost per part. The multi-head standard package options have two and four cutting heads and can be expanded on.
Also, depending on the application, the multi-head solutions can be paired with higher horse power pumps so there is no performance loss at the individual cutting head. For consistent abrasive delivery, each head has its own dedicated mini hopper, and each head can be turned on and off independently so only those needed are engaged in cutting. An auto spacing feature makes adjusting the cutting head spacing fast and simple with 48″ maximum and 5.5″ minimum spacing between heads.
Machines Deliver Precision in Profiling
HSG Laser’s (Addison, IL) PRA Series Optical Fiber Laser Cutting Machines enable efficient, precise section cutting and profiling, including custom graphic cuts, grooving and structural detailing. Each cut is characterized by exceptional precision, smooth edges, and minimal slag hanging, for simple and easy operation.
Fully integrated with Tekla® software, the PRA Series supports rapid production scheduling, automatic material list generation, one-click nesting, and seamless processing code output — making operation simple and efficient from the start to finish.
Compared with plasma cutting, the PRA Series offers a cleaner, faster, and more stable solution without the risk of thermal stress deformation. Each machine includes advanced calibration and compensation technology for smooth section cutting and one-time forming accuracy. Additional features include automatic remnant nesting, short-tail cutting, zero clamp interference, and unrestricted cut-off nesting, maximizing material utilization and production flexibility.
The technical specifications of the HSG PRA Series include laser power ranging from 12,000 W to 20,000 W, a maximum pipe length of up to 40’, X–Y positioning accuracy of ±0.0059”/m, and X–Y repositioning accuracy of ±0.0039”/m. With its horizontal bi-directional swing cutting head, the PRA Series provides 0°-to-180° horizontal rotation for enhanced cutting range and flexibility.
New 3D Laser Cutting Machine
Prima Power North America’s (Arlington Heights, IL) Laser Next Core is the newest addition to its 3D laser cutting range. Compact, cost-effective, and easy to use, Laser Next Core is designed for job shops and flexible manufacturing environments. With axis strokes of 3,160-x-2,100-x-750 mm, the Laser Next Core can handle parts of any size and geometry. It ensures high quality even with frequent production changeovers, offering outstanding performance in both 2D and 3D cutting, as well as optional welding applications. Typical applications involve limited batch sizes (less than 1,000 parts per batch), where quick setup and production changeover are crucial.
Laser Next Core achieves minimum cost-per-part, up to 25% lower than market references. This is accomplished through optimized fixed and running costs, reduced labor intervention, minimal maintenance effort, and limited gas and power consumption. Its outstanding versatility ensures maximum floor space efficiency with a working volume 58% larger in its class and a footprint 25% smaller. Machine operation is further simplified by one-click programming, an intuitive HMI with graphical teach panel, and automatic head-offset compensation by local head axis, making high-performance 3D laser cutting easier and faster than ever.
AI Improves Laser Cutting Edges
TRUMPF’s (Farmington, CT) Cutting Assistant application uses AI to help users improve the quality of laser-cut edges. Production employees take a picture of their component’s cut edge with a hand scanner. Then, the solution assesses the edge quality, evaluating it using objective criteria such as burr formation. With this information, the Cutting Assistant’s optimization algorithm suggests improved parameters for the cutting process. Then the machine cuts the sheet metal once more. If the part quality still does not meet expectations, the user has the option to repeat the process.
The AI evaluates the edge quality and makes optimization suggestions. By integrating the Cutting Assistant into the machine software, optimized parameters can be transferred seamlessly into the software without the need for programming, which saves time and reduces errors. Further improvements are planned for the Cutting Assistant. TRUMPF regularly provides users with online updates to download to their machines for maximum productivity and quality.
