Laser Cutting Machines: CO2 versus Fiber Lasers
Keep that old CO2 laser or invest in a new fiber laser? It’s a common question for metal fabricators, and one with many financial ramifications. The right laser yields accurate and fast cutting, and ultimately, faster project completion and increased capacities.
We’ve been privileged to be part of many manufacturers’ decision process between CO2 and fiber lasers. Our company has been selling fiber lasers for more than 10 years and has seen the benefits for our customers first-hand. Here is an overview of the benefits of fiber lasers we’ve seen compared to Co2 laser technology.
CO2 vs Fiber Lasers Overview
When first introduced 50 years ago, CO2 lasers were a major revolution in manufacturing. Manufacturers scrambled to add them to their equipment line-up because of their ability to cut many materials and deliver a precise edge quality. Their technology is based off a fairly reliable concept. In a CO2 laser, electricity flows through a tube filled with a combination of gases. The light created is reflected into an intense beam that cut through a variety of materials. These machines became more commonplace over the years because of their proven technology.
A fiber laser is a much more recent invention, though modern fiber laser technology has evolved in major leaps and bounds in a very short time frame. A fiber laser utilizes excited gas molecules to make a very intense beam. The beam has a shorter wavelength and (therefore) a higher absorption rate than CO2 lasers, which translates into some very real benefits discussed below. Those benefits---both productivity and financial---are continually increasing as fiber laser technology evolves by leaps and bounds. Fiber laser manufacturers are continually developing more powerful and accurate fiber lasers with the capability to cut more metals and thicknesses.
These lasers work differently, and, therefore, each type of laser comes with its own set of pros and cons.
Fiber Laser Pros
Maintenance Free
Fiber lasers require no beam path maintenance over the life of the machine, while lasting as long as a CO2 laser. Modern fiber lasers can log hundreds of thousands of hours over the life of the machine. CO2 lasers require maintenance of the lenses and other components throughout its lifespan. These tasks translate into additional costs and downtime.
No Warm-up Time
Unlike CO2 lasers, fiber lasers can start cutting with no warm-up time. Warm-up time in a CO2 laser is typically 10 minutes after every start-up. Over the life of the machine, this cutting time can yield significantly more cutting time.
Less Energy Use
Though fiber lasers produce incredibly powerful beams, they actually use less energy use compared to CO2 lasers. With a long machine life, the savings add up over time. According to world-class fabricating equipment manufacturer Bystronic, the electrical efficiency of a fiber laser is up to 5 times greater than a CO2 laser. Additionally, by Bystronic’s calculations, one 10 kW fiber laser can use significantly less energy than two CO2 lasers (a 4.4 kW and 6 kW) and yield a power savings of 212’940 kWh/year.
Faster Cutting Speeds
Fiber lasers cut significantly faster then CO2 lasers, especially on thinner materials (1/2 inch and less), because its beam is absorbed by the material with less reflection than CO2 lasers; in some cases, fiber laser speeds have proven to be 5x faster than CO2 lasers. Our customers are also seeing real benefits by utilizing the latest laser gas assist technology (including on-site, cheaper nitrogen generation systems and gas mixers). The faster speed of the fiber laser means more parts cut and more capacity.
Manufacturers can also benefit from the greater absorption rate of the fiber laser when cutting copper, aluminum and brass. Fiber lasers are more efficient and safer when cutting these materials compared to CO2 lasers because there is less reflection than with CO2 lasers.
Smaller Footprint
Though more powerful, fiber lasers occupy a smaller footprint than CO2 lasers. Our customers often utilize the “extra” space can be used for other operations or for productivity-boosting and labor-saving laser automation. The latter solution has enabled manufacturers to boost their productivity and utilize their workforce more efficiently.
CO2 Laser Pros
Lower Up-Front Cost
The up-front cost of CO2 lasers is typically less than fiber lasers. However, with lower operational costs and less maintenance costs, the fiber laser typically has a faster return-on-investment.
Can Cut More Materials
CO2 lasers can cut metals and non-metals, while fiber lasers can only cut metal. These lasers can even cut a long list of materials, such as wood, ceramics, and glass. With a CO2 laser, manufacturers have the ability to take on a larger variety of projects.
Better Edge Quality on Thicker Materials
Since their invention, CO2 lasers have always been known for their edge quality. Today, they still marginally outpace the fiber laser. However, fiber laser technology is closing the gap in this area as power surges and their ability to cut thicker materials efficiently increases.
Faster first cuts and straight line speeds
This area is also a tight race between the lasers. CO2 lasers deliver faster first cuts and straight line speeds, though more powerful fiber lasers can typically complete projects faster because of their ability to cut faster overall.
Summary
The answer to the question, “CO2 laser or fiber laser?” depends on a number of factors. Manufacturers should consider the amount of capital available for purchase, as well as the overall costs associated with the machines. Though CO2 lasers cost less up front, they have higher operational and maintenance costs over the life of the machine. CO2 lasers also cost manufacturers more over the life of the machine because they require more downtime for warm-up and maintenance. They do offer fabricators the chance to cut more materials, though their cutting speeds are slower than a fiber laser.
In pure terms of speed, two CO2 lasers can be replaced by one fiber laser---and achieve the same productivity (or even surpass it) while costing manufacturers less in maintenance and energy use over the life of the machine. We’ve seen fiber lasers outperform CO2 lasers in almost every area, and earn our customers more business with a higher cost-per-part profit margin. Fiber lasers are faster, cheaper to run, and give manufacturers the ability to accept more jobs because they can be completed quicker.