Laser technology has made many industrial processes quicker, more efficient, and more accurate. Many different kinds of laser systems are available, but one of the most popular for cutting and engraving is the flatbed laser. Flatbed lasers have a huge variety of applications in the industrial world, from signage production to metal fabrication. So, how do flatbed lasers work, and most importantly, what are the main advantages of using them in an industrial setting?

What are Flatbed Lasers?

As the name suggests, a flatbed laser cutter has a flat working surface where the materials are worked on and a moveable laser head. Most flatbed laser machines will work with various materials, including metal, plastic, textiles, and wood. The design is programmed into a computer, which then controls the laser, allowing for complex designs and a high degree of accuracy compared to other cutting methods. 

The Advantages of Using a Flatbed Laser

1. Efficiency and Speed

One of the biggest advantages of flatbed lasers is the speed and efficiency with which they can complete a job. Because a laser is used for cutting or engraving, it doesn’t have contact with the material, so there’s minimal friction. This allows the job to be carried out much faster. You’ll notice how much smoother the process is when you compare this to mechanical tools. Whether it’s a small batch or a large volume being produced, you’ll notice increased efficiency and productivity in your processes. 

2. Multiple Materials Can be Used

Flatbed lasers are incredibly versatile when it comes to the materials that can be cut or carved. If you need to switch between different materials, you can do so without needing to switch tools, which has traditionally been a time-consuming process. 

Some of the materials that can be engraved or cut with flatbed lasers include:

  • Most metals
  • Plastics
  • Acrylic
  • Leather and textiles
  • Ceramics
  • Stone
  • Wood

It’s no surprise that this versatile method is used in a variety of industries, from automotive to packaging, textiles, signage, and many more. Lots of different types of cuts and engraving can be carried out on the above materials, opening up the potential for new products and innovations. 

3. Accuracy and Precision

Flatbed lasers can create very precise engravings and cuts. Because of the high levels of control the machine has over the laser as it melts or vaporises the material, designs that were previously impossible using other methods can be achieved. You’ll also find that there are minimal tolerance errors compared to other methods of cutting.

You’ll also find with mechanical cutting methods, over time, the tools will suffer from wear and tear, which affects the cutting accuracy. This can mean you need to constantly calibrate, sharpen, or replace the tools, which adds additional time to the process. Flatbed lasers keep their accuracy even when working on long processes, saving time and ensuring high precision no matter how long they’re used. While components will sometimes need to be replaced, they tend to stay efficient for as long as they’re in use. 

4. Reduction in Materials Waste

Traditional cutting methods can damage the material around the cut, which means some of the material is then wasted. This is bad business practice if you’re working with expensive or difficult-to-source materials, as you’ll want to minimise waste as much as possible. Laser cutting uses a narrow beam, so the kerf, which is the width of the cut, can be extremely fine. This means there’s less effect on the surrounding material. They cut smoothly without drag, allowing for clean cuts that are extremely thin.

Flatbed laser machines are also controlled by complex software, which calculates the best cutting paths. Not only does this make the job quicker, but it also means it can work out the most efficient way to cut the material to get the most out of it and minimise scrap. Not only does this save you money, but it is also a much more eco-friendly way to approach production. 

5. Complex Designs Can Be Achieved

Flatbed lasers are ideal for jobs that need a high degree of precision, such as intricate designs or patterns. This is why they’re often used in industries such as jewellery-making and electronics. Sharp corners and complex geometric designs are much easier to create with a flatbed laser than traditional cutting tools. Some examples of uses include the creation of circuit boards, where small, precise cuts need to be made, or adding complex engraving to jewellery, which would be almost impossible to achieve using hand tools, even by artisans. You simply upload the design and let it do the work, creating the design you have in your mind. 

6. Fewer Secondary Finishing Methods are Needed

Some methods of cutting require post-processing. This could mean sanding, polishing, or grinding the materials to give them the desired finish. Secondary finishing is often necessary with older techniques as you can end up with burrs or rough edges, so they’ll need to be finished off for practical and aesthetic methods.

When you use a laser for cutting, the cuts are much cleaner and smoother, so minimal post-processing is needed. If you want to make your production times shorter and reduce labour costs, switching to a flatbed laser could help you achieve your goal. 

7. Safety

When used correctly, laser technology can be much safer for operators than traditional cutting and engraving methods. Modern flatbed lasers have features such as laser shields, enclosed work areas, and automatic shut offs, which make them very safe for anyone operating them. There are no sharp tools, and no contact is made with the material, so there are fewer things that could potentially cause accidents. Much of the process is automated, so operators won’t need to make many manual interventions, so the risk of human error is reduced. This is reassuring, as it means there is a lesser chance of accidents or workplace injuries. 

8. Automation and Software Integration

Flatbed lasers can be integrated with a wide range of software to automate cutting and engraving processes. This can make them much more efficient and faster. CAD or CAM software can be used to create precise plans, which are then uploaded to the machine. Both engineers and designers usually have familiarity with these types of software, so should find the process easy. 

Another advantage of this type of software is that it’s easy to make adjustments and move between projects. There’s less space for human error and more potential for custom designs. Calculations such as the shortest cutting path are worked out for you, which makes the processes simpler and means there’s less for engineers to plan. 

9. Lower Energy Consumption

The operating costs of flatbed lasers tend to be cheaper than mechanical cutting systems. They don’t use as much energy as mechanical methods, as they don’t require as much force or heat to use. They can also be cheaper in terms of the materials used and maintenance, making them less expensive in the long run. Overall, the investment in a flatbed laser tends to be more expensive as the machinery is more complex, but when you factor in the long-term savings, not to mention the improvement in efficiency, you will no doubt find it’s worth that initial upfront cost.

10. Simplified Maintenance and Tooling

Finally, a big advantage of flatbed laser equipment is the simplicity of tooling and maintenance. If you think about traditional cutting machines, you have lots of tooling, from saws to dies and blades. All of these suffer from wear and tear over time, which means they need to be replaced. This means downtime and costs for your business. Laser cutting doesn’t require physical cutting tools; everything is done with the focused laser beam, so you don’t need to maintain, replace, or switch tools between jobs.

Maintenance of flatbed lasers is also straightforward. Regular cleaning keeps them running well, and you may need to occasionally replace components as the machines get older. This means you’re likely to spend less overall on parts and maintenance, as well as having less downtime for cleaning and repairs, saving your business money. 

In Conclusion

While flatbed lasers are a bigger monetary investment than other cutting tools, they can save money and time in the long term. There are many reasons why flatbed lasers are a great investment in an industrial environment and why they are used extensively in industries such as aerospace, electronics, and automotive, among others. These machines combine precision, speed, and versatility while also being cost-effective to run. Using a flatbed laser in your production process can help reduce costs and improve productivity. 

Want to find out more about flatbed lasers and how they could help improve your manufacturing process? The Bend Tech Group creates a huge range of industrial machinery and works with clients across all sorts of industries. Simply start a live chat or contact us online to tell us about your project.