There are many ways of cutting metal, but some are more precise than others. In this article we will look at how laser, plasma, and waterjet cutting have affected the precision of modern sheet metal cutting compared to what is achievable with traditional shearing and die cutting. For sheet metal fabrication, at Taiwa we find combining modern punching techniques with laser cutting delivers the optimum results.
Why is precision cutting so important in sheet metal fabrication today?
Accurate cutting is of the utmost importance in sheet metal fabrication, especially in the cost-conscious world of 2024. Precision cutting increases productivity by reducing the need for additional deburring and finishing work, and can speed up the workflow, especially when used efficiently with other cutting tools.
Traditional shearing, die cutting, and punching techniques of sheet metal cutting need to be carefully controlled to avoid excessive distortion or stresses to the surrounding material. Laser cutting causes no mechanical stress, and with the correct programming heat transference is easily controlled.
Does every cut need to be precise?
For high volume, high speed cutting of straight edges, shearing is a logical choice if absolute precision is not required. Plasma cutting enables very rapid cutting of thick materials, but tends to create rough edges that need additional finishing.
If you’re not sure, just ask us
If you are looking for very high throughput and your engineering requirements do not call for high precision we will advise you how we can carry out a job to your specifications using the most efficient cutting methods available.
What are the most precise sheet metal cutting techniques?
Today we have a choice of technologies for metal cutting. Laser cutting can be used to cut very complex and intricate shapes, with minimal heat distortion, and without the compressive and bending stresses associated with shearing techniques. Accuracy to 0.1mm or better is routinely achievable with laser cutting. At Taiwa we find we can best meet our customers’ needs for sheet metal fabrication by laser cutting in preference to all other techniques.
What are examples of the maximum cutting depth for laser cutting?
- Steel SPCC 22.0 mm
- Stainless Steel SUS304 12.0 mm
- Aluminum AL5052 10.0 mm
- Brass 8.0 mm
- Copper 5.0 mm
Is water jet cutting a good method for sheet metal cutting?
Water cutting uses a water jet loaded with abrasives to cut a wide range of materials and used to be one of the most accurate cutting technologies. Improvements in laser cutting technology have made water cutting less attractive for cost, accuracy, and convenience reasons. Taiwa uses AMADA laser cutting machines that can cut pipe and hollow sections, which used to be impossible to cut accurately with lasers.
Precision laser cutting is superior to plasma cutting
Plasma cutting has similar precision to water cutting, and is effective for cutting thick metal sheets, but is much less precise than laser cutting and needs more deburring and finishing of cuts. Modern laser cutting machines, like the Japanese AMADA CO2 and fiber machines we use, are capable of cutting a wider range of metals and thicker sheets, avoiding the need for plasma cutters.
Does precision depend on the material being cut?
Mechanical cutting of materials tends to create very different results depending on the physical properties of the material. Very hard metals might shatter under shearing forces, soft metals tend to stretch and distort. Laser, plasma, and water jet abrasive cutting can achieve predictable tolerances across a wider range of materials than can be easily managed by mechanical shearing.
With laser and plasma cutting you add heat to the material, and this requires careful control of the intensity of the laser beam or plasma arc to minimize distortion. Computer controlled laser cutting machines manage this as part of the cutting process, and are programmed for the exact thickness and type of material to minimize area heat transfer in the cutting process.
What about die cutting, press stamping & punching?
For high volume, mass production of identical parts, especially in thin metal sheets, punching is very much the go-to technique. The precision of the result is dependent on the accuracy of the die used, and the high pressure shearing forces cause some distortion and compression of the resulting component that has to be built into the engineering design and manufacturing process.
Die cutting and press stamping are excellent techniques when carried out correctly to maximize accuracy and minimize wear to the punches and dies used. Small errors in engineering design will accelerate wear on the cutting edges and reduce accuracy very rapidly, so expert input at all stages of the design and use of dies and stamps is essential.
Can you combine punching with precision laser cutting?
The short answer is yes, you most definitely can do this, and combining well engineered, high precision punching tools with laser cutting offers a method for achieving very accurate results at high speed for optimum efficiency. Maximum thickness for punching is 2.0 mm, which meets the requirements of most sheet metal fabrication projects.
Taiwa laser cutting & punching for rapid, controlled precision
At Taiwa we have three AMADA Japanese manufactured AMADA LC2012 combination CNC turret punch laser cutting machines, which give us the best of both worlds, enabling us to carry out cutting and punching operations during the same pass over the metal sheet. This reduces material handling, increases accuracy, and optimizes workflow for high speed, cost effective sheet metal fabrication.
Comprehensive sheet metal fabrication services from Taiwa
We have more than 20 years of experience in sheet metal fabrication, and offer a comprehensive range of sheet metal fabrication services, including design, cutting, bending and assembly of sheet metal components. Our wide ranging expertise can be seen in our case-studies.
Taiwa quality is ISO 9001 and ISO 14001 certified and we are recipients of the Taiwan TTQS Workforce Quality Certification for our in-house staff training and development programme. Contact us today to discuss how we can deliver the best possible solution for your cutting and fabrication requirements.
