November 2022 - Hallmark Nameplate

Are you designing and manufacturing a metal nameplate for your business?
Struggling to find a fabricator who can cut your intricate design, without long lead times?
When it comes to manufacturing your nameplate, it all comes down to the machine that’s cutting the material.

But which machine is the best one to produce precise cuts quickly?

Introducing: laser cutting.

So, what is laser cutting, and what are its benefits?

In this article, we will explain:

The three different types of laser cutters
5 benefits of laser cutting
IPG’s Photonics’ LaserCube
Where you can get the best metal fabrication

Let’s dive in!

What Is Laser Cutting?

First, let’s begin by explaining that laser stands for light amplification by stimulated emission of radiation.

Laser cutting is the process of using a laser to cut or engrave materials. It is often used for thicker metals that normal machines cannot cut through.

A laser cutter is a computer numerical control, or CNC, machine. This means it is controlled via a computer – not manually by a person. Using design software, the manufacturer can put in a precise design, and the cutter will automatically create it.

Types of Laser Cutters

There are three types of laser cutters:

CO2
Neodymium
Fiber

But what are their differences? Keep reading to find out.

What Is CO2 Laser Cutting?

This laser is created through electrically stimulated gas, mostly carbon dioxide. It is not as strong as the other cutters, so it is best for softer materials.

What Is Neodymium Laser Cutting?

There is neodymium (Nd) and neodymium yttrium-aluminum-garnet (Nd:YAG) formed with neodymium-doped crystals. Nd cutting is typically used for high-energy and low-repetition boring while Nd:YAG is best used for high-power boring.

It has a smaller wavelength than CO2 lasers. This means it has a higher intensity, so it can cut through thicker materials. But because of the high intensity, its parts wear faster.

What Is Fiber Optic Laser Cutting?

This laser is made up of what is called a “seed laser.” This process uses a high-power laser that is directed through optics as well as CNC.

The laser is moved with a motion control system to cut a pattern into the metal, leaving high-quality edges. Additionally, you can vary its focal length, allowing you to cut different layers and varying depths.

While it works at the same wavelength as Nd lasers, it requires less maintenance due to its non-moving parts.

How Does Fiber Optic Laser Cutting Work?

So, where does the laser come from? It is created when lasing materials are formed by electrical discharges in a confined space.

With a partial mirror, the lasing material is reflected and amplified until enough energy is created to make a stream of coherent monochromatic light. The light is directed by fiber optics through a lens onto the work area.

As it hits the material, it melts a micro pit and creates an anti-shock wave.

5 Benefits of Laser Cutting

There are several benefits to using all laser cutting systems, but we recommend fiber optic laser cutters. Here are 5 advantages to using laser cutters for your fabrication projects.

1. Quick Turnaround

Unlike most cutting processes, laser cutting is not messy and requires less cleanup or post-cutting sanding. This means you do not have to have as much downtime between sets.

Additionally, it is more efficient and cuts at a faster rate than manual cutting, or even other laser cutters. This means you can produce larger quantities in a shorter amount of time.

2. Affordability

From initial purchase price to lifetime costs, fiber optics saves a lot of money for manufacturers and in turn gives customers, like you, a cheaper price. Using fiber optic laser cutting reduces maintenance by about 50% because its parts are reliable with fewer moving parts and mirrors.

Not only that, but it produces less material waste, because the kerf width is very thin, and it consumes less energy, which translates to lower costs.

3. Intricate Design Capability

Another benefit of fiber optic lasers is that it produces more precise cuts because the light beam does not wear down. You also consistently get high-quality results because there is no chance of human error.

Using fiber optic laser cutting, you can create complex designs on smaller parts. This high level of accuracy makes it perfect for creating medical devices.

4. Works On Any material

Laser cutting is perfect for any application; it is not limited to any material because it can cut material up to .86” thick. It works on plastic, wood, paper, cardboard, or metal, including stainless steel.

It also has the ability to cut materials that are reflective without the worry of back reflections causing damage to the machine. This means you can cut copper, brass, and aluminum.

5. Energy Efficient

Laser cutters are generally more energy-intensive than other cutting methods, but Fiber-optic lasers are far more efficient than CO2. It uses about one-third the amount of energy and a quarter of the power of other lasers.

Fiber optic lasers require no gases, eliminating toxic emissions.

The Best Fiber Optic Cutter, IPG Photonics’ LaserCube

IPG Photonics is a leader in fiber lasers, developing lasers since 1990.

This flatbed fiber laser cutter offers 2 kW average power and 4 kW max peak power. This machine is very reliable and has low operating and part-processing costs.

It uses high-force linear motors and has the stability and acceleration perfect for cutting small parts precisely.

Get High-Quality Metal Fabrication With Hallmark Nameplate

Tired of long lead times and sloppy cuts? Need a machine strong enough to cut through stainless steel or thick metal? Give Hallmark Nameplate a call.

Get high-quality custom metal fabrication for any application at a fraction of the time and cost of other manufacturers.

We use only the best technology, which is why we’ve invested in IPG’s Fiber Optic LaserCube. We can custom fabricate any intricate design with precise cuts for our customers every time.

Ready to get started? Visit our website or call 352-383-8142 to request a free quote.

As a business owner or manager, you are always looking for ways to improve your business and make more money.

But instead of trying to cut corners in production, you should work to maximize your business’s productivity. But how?

Improving your overall equipment effectiveness is a great place to start.

But what does that mean, and how do you get started on making changes?

In this article, we will discuss:

How to calculate your overall equipment effectiveness so you can see where you started and track your progress.
7 ways you can enhance your productivity and in turn improve your OEE.
Where you can manufacture high-quality equipment to improve your OEE.

Let’s dive in!

How To Calculate Overall Equipment Effectiveness

First lets, discuss what overall equipment effectiveness (OEE) means. It is the percentage of planned production time that actually ends up being productive.

100% = perfect production
85% = top of class
60% = average
40% = starting off

As you can probably guess, your ultimate goal is 100%, but 85% is a more practical, long-term goal for most companies.

OEE Formulas

There are two different ways you can go about calculating your overall equipment effectiveness. The latter is preferred because it provides more information on the underlying factors for loss in productivity.

OEE = (Good Count × Ideal Cycle Time) / Planned Production Time

OEE = Availability * Performance * Quality

Availability = Run Time / Planned Production Time
Run Time = Planned Production Time − Stop Time

Performance = (Ideal Cycle Time × Total Count) / Run Time

Quality = Good Count / Total Count

OEE Definitions

Here are a few definitions to help understand the formulas.

Good count: parts manufactured without defects
Ideal cycle time: the estimated fastest possible time to manufacture one part
Planned production time: time the production part is scheduled for production

If your OEE is at 60% or below, then you need to get serious about improving your productivity.

7 Ways You Can Improve Your Business’s Productivity & OEE

When you take longer on projects than expected, it can affect your finances. From having to pay more for facility rent and your employee’s time to taking on fewer clients, your costs are likely to increase while your profits will only decline.

Here are 7 ways you can improve your productivity and overall equipment effectiveness and in return earn more profits.

1. Improve Staff Efficiency

Is your staff producing at lower levels than you’d like? It may be because of the equipment they are using.

When their controls and switches aren’t easy to use, it can cause speed loss and delays in their production. By designing your equipment internally with a manufacturing partner, you can take into account what your employees need.

Take a look at how they interact with the controls currently, what they use often, or what is obsolete. From there you can design a user interface that is seamless for your employees to use.

2. Minimize Errors & Safety Issues

When your employees don’t know how to use their equipment, it can lead to injuries and malfunctions.

With graphic overlays and labels, you can ensure there are clearly marked instructions on the equipment. When there are fewer mishaps on the production floor, everyone can work efficiently, and there is no need for downtime.

Additionally, clear instructions can save you time because now your employees know the most efficient way to use the equipment instead of playing guessing games.

3. Decrease Downtime

As any business owner knows, time is money. Therefore, downtime is just your business hemorrhaging money.

When your equipment has an electronic failure, sometimes you have to shut down production entirely to fix or replace the broken part. That’s why it is important to work with a manufacturing partner who tests all electrical components to ensure high-quality electronic assembly.

With tactile switches, you improve the durability of your equipment so you do not have to stop to replace switches as often. Additionally, you can use them as often as you’d like without worrying about burning them out.

4. Reduce Cleanup

There’s nothing worse than having to repeatedly stop your work to fix a machine or give your tools a heavy-duty clean. With graphic overlays, you can add an extra protective layer to your equipment to increase its lifespan and reduce the need for maintenance and cleanup.

Additionally, using membrane switches instead of mechanical switches can reduce cleanup, requiring only occasional dusting.

5. Increase Visibility

Industries that use heavy-duty equipment, such as agriculture need complete visibility to maintain safety. Therefore, during dark or extreme weather conditions, they need to stop working for the day or move slowly.

Backlight membrane switches allow workers to see controls in dark or stormy conditions so they can continue to work efficiently- rain or shine. You can choose between electroluminescent (EL) or light-emitting diode (LED), although LED lasts longer and is more energy efficient.

6. Eliminate Confusion

As we mentioned earlier, when your staff can’t work their equipment correctly, they won’t be efficient. If they are not able to easily locate their controls, it can lead to longer production times.

Membrane switches with embossed areas and tactile feedback allow the operator to quickly distinguish the control pad when the area is embossed or raised to the next level. For even greater touch recognition, perimeter or dome embossing of individual keys reduces operator selection errors.

7. Increase Response Rate

If your equipment utilizes touch screens like smartphones or tablets, then they may be suffering from delays and errors due to technical issues.

Tactile membrane switches allow the device they are integrated into to be more responsive. Therefore, your team can utilize their devices with fast response rates and improve their overall results.

Additionally, with increased responsiveness, the device is more capable of handling several tasks at once so your staff can get more done in a fraction of the time.

Improve Your Productivity With Hallmark Nameplate

Looking to improve your business’s productivity and overall equipment effectiveness? At Hallmark Nameplate, our expert team of designers and manufacturers will work with you to design the perfect equipment for your needs.

From durable and clear graphic overlays to high-quality membrane switches and electronic assemblies, we will make sure your team can efficiently use your equipment.

Want to learn more? Visit our website to request a quote or get in contact with our experienced staff members.

Month: November 2022

What Is Laser Cutting & How Does It Work?