1. Laser Cutting (Sheet Metal Cutting by Laser)
Laser cutting is a high-precision thermal cutting process that uses a focused laser beam to melt, burn, or vaporize material, typically sheet metal, along a programmed path.
🔹 Process Description:
A high-power laser beam (commonly CO₂, fiber, or Nd:YAG) is directed through a nozzle and focused on the material surface.
Assist gases (oxygen, nitrogen, or compressed air) are used to enhance cutting quality, eject molten material, and prevent oxidation.
The laser head follows a CNC-controlled path to achieve intricate shapes and complex geometries with minimal heat distortion.
🔹 Materials:
Carbon steel, stainless steel, aluminum, brass, copper, etc.
Common thickness range: 0.5 mm – 25 mm (depending on material and laser power)
🔹 Advantages:
High precision and edge quality (kerf typically <0.2 mm)
No need for additional finishing (burr-free in many cases)
Ability to cut complex contours with tight tolerances
Minimal material deformation due to small heat-affected zone (HAZ)
High repeatability and automation via CAD/CAM integration
2. CNC Press Brake Bending (Abkant Bending)
Press brake bending, often referred to as Abkant bending (from German), is a cold-forming process used to bend sheet metal using a hydraulic or electric press brake equipped with upper (punch) and lower (die) tools.
🔹 Process Description:
The sheet metal is positioned between a V-shaped die and a corresponding punch.
The CNC-controlled ram (upper beam) forces the punch into the die, plastically deforming the material along a straight axis.
Backgauges and CNC systems ensure precise part positioning and bending angles.
🔹 Bending Types:
Air bending (most common) – The punch doesn’t fully bottom into the die; allows for angle flexibility.
Bottom bending – The material is pressed fully into the die for greater accuracy.
Coining – High-pressure bending for very tight tolerances and minimal springback.
🔹 Capabilities:
Bending length: Depends on machine (commonly 1000 mm to 6000 mm or more)
Bending force: Depends on material thickness and type (measured in tons)
Bend angle accuracy: ±0.2° or better on CNC machines with angle measurement systems
🔹 Materials:
Mild steel, stainless steel, aluminum, brass, and other sheet metals
🔹 Advantages:
High precision and repeatability due to CNC control
Multiple bends can be programmed in a single setup
Reduced setup time with automatic tool changing systems (on high-end models)
Suitable for both prototyping and high-volume production
🔩 Combined Process Workflow:
Laser Cutting: Flat pattern is cut from sheet metal with precise profiles and cutouts.
CNC Bending: Cut parts are transferred to the press brake for bending operations based on design specifications.
Quality Check: Final parts are inspected for dimensional accuracy and angle precision.
