Introduction
In today's rapidly developing manufacturing industry, the evolution of cutting methods has become a key to enhancing corporate competitiveness. Traditional plasma cutters, despite their low cost and high speed, are gradually falling short in terms of precision and flexibility. The advent of fiber laser cutting has not only brought about a fivefold increase in precision but also the ability to handle a variety of metal materials (such as copper, aluminum, galvanized steel, stainless steel, etc).
Nowadays, through the solution of converting plasma cutters into fiber laser cutters, small and medium-sized factories can make the leap from traditional equipment to high-end intelligent machinery without having to replace the entire machine.
The Differences Between Plasma and Fiber Laser
Working Principle of Plasma Cutters
Plasma cutters use a high-energy plasma arc to cut metal. When an electric current passes through a gas, it ionizes the gas, forming a high-temperature, high-speed plasma stream. This plasma stream releases a large amount of energy when it contacts conductive material, instantly melting the material.
Working Principle of Fiber Laser Cutters
Fiber lasers use solid-state technology. Light is generated by diode lasers and transmitted through optical fibers doped with rare earth elements such as ytterbium. The output wavelength is approximately 1.06 micrometers, which is very suitable for metal processing. The beam is directly transmitted to the cutting head through an optical fiber cable, without the need for mirrors or complex alignment systems.
Main Differences
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Cutting Method and Precision: Laser cutting achieves melting or vaporization through a focused beam, resulting in smaller kerfs and higher cutting precision. Plasma cutting, on the other hand, uses a high-temperature plasma arc to melt material, resulting in larger kerfs and relatively lower precision.
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Cut Quality: Laser cutting produces smooth and flat cuts that require almost no post-processing. Plasma cutting has a larger taper on the cut, making it suitable for users who do not require high cutting precision and have no cross-sectional requirements.
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Cost: In terms of initial investment, plasma cutters are relatively inexpensive, while fiber laser cutters have a higher cost. However, in the long run, fiber laser cutters are more cost-effective in terms of investment and operating costs.
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Environmental and Health: Laser cutters produce very little dust; plasma cutting generates a significant amount of dust, which can cause greater harm to human health. In cities with environmental requirements, laser cutting is more in line with standards. When paired with our dust collector, laser cutting can achieve zero pollution.
Core of the Retrofitting Solution: What Do We Need to Prepare?
Project Objective
To systematically upgrade a standard plasma cutter to a high-performance fiber laser cutter through a DIY approach.
Core Material List
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Main Equipment: Laser source, water chiller, laser cutting head, cutting system, voltage stabilizer, flame cutting head (optional).
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Key Components: Custom "SKY FIRE" laser beam (gantry).
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Electrical and Control: Electrical cables, control panel, electrical control cabinet, pneumatic module, etc.
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Auxiliary Tools: Lifting equipment, measuring and installation tools, etc.
If you need a complete bill of materials for plasma to fiber laser conversion, please click here to obtain it.
Information You Need to Provide and Material List to Be Modified
Rack Model and Size Information
To ensure the correct meshing of gears, we need to know the specific model and size of the rack.
Track Width Parameters
Please provide the detailed dimensions of the track width so that we can accurately install and position the wheels.
Center Distance Between Two Rails
We need the center distance between the two rails to determine the length of the beam. If you have a fixed length requirement, please also inform us.
Processing format
We need to confirm the length of the drag chain and the length of the pay-off.
Material List to Be Modified
Please provide the material list that needs to be modified. The standard configuration of the beam is to place it on the left side. If there are special requirements, please specify separately.
Step-by-Step Guide to Retrofitting a Large Format Plasma Cutter to a Fiber Laser Cutter
Step 1: Project Initiation and Basic Dismantling
This initial stage aims to lay the foundation for the new high-performance laser system. Our technical team will follow strict safety and efficiency standards to systematically dismantle and remove the original plasma torch, related power supply systems, and old gantry. This step is not only about preparing the physical space but also ensuring that the subsequent installation is precise and error-free, establishing a professional and rigorous project image.
Step 2: Core System Integration - Precision Installation of Customized Gantry
The core task of this stage is the precision hoisting and positioning of the customized laser gantry and the integration of the laser cutting head. This step is the decisive step in realizing the concept of "customized solutions for small and medium-sized enterprises." Through precise engineering calculations and matching, we ensure seamless integration and perfect compatibility of the new gantry system with your existing equipment frame.
Step 3: Technical Core Commissioning - Optical and Electrical System Integration
In this technical core stage, our engineers will perform a series of precise operations, including the laying of the optical path (optical fiber cabling), connection of the cooling system, and joint commissioning of the entire electrical system. During this process, engineers will explain key technical nodes to ensure that all subsystems work together at their best, providing assurance for the final excellent performance output.
Step 4: Final Verification and Performance Demonstration
The final stage is a comprehensive verification of the retrofitting results. We will first optimize the process parameters finely and then demonstrate the excellent high-speed and high-precision performance of the fiber laser when cutting thin plates. Next, we will switch to the "flame" cutting head to visually demonstrate its strong penetration and cutting capabilities when dealing with thick plates, fully presenting the dual functions and powerful capabilities of the upgraded equipment.
Why Is This a Leap, Not Just an Upgrade？
Dual Function Integration and Comprehensive Service
Our solution is much more than a simple equipment upgrade. It integrates the dual functions of fiber laser and flame cutting: on the basis of transforming your plasma equipment into a high-precision fiber laser cutter, we also offer an optional "flame" cutting head. This innovative integration greatly expands your processing capabilities for thick plates, allowing you to handle various processing needs from thin to thick plates with ease, achieving multi-functionality in one machine. To ensure seamless integration and excellent performance during the retrofitting process, we provide one-stop services from core material supply, professional installation guidance to precise technical commissioning, allowing you to experience the professionalism and reliability of our technical team at every stage.
Leap in Performance
This retrofit aims to "rebirth" your equipment. We retain the sturdy and durable frame of your existing equipment and inject it with high-precision cutting capabilities representing the cutting-edge technology in the industry. After the upgrade, your equipment will achieve a leap in quality, bringing a qualitative leap to your productivity.
Smart Investment Tailored for Small and Medium-sized Enterprises
We deeply understand the budget challenges that small and medium-sized enterprises face when upgrading technology. Therefore, this retrofit solution is designed as a smart investment strategy, enabling you to unlock and own world-class production capabilities in a cost-effective manner without having to bear the huge capital expenditure of purchasing new large-scale equipment, thereby gaining a significant competitive advantage in the market.
Excellent Cost-Effectiveness and Return on Investment
By reusing your existing gantry platform and original frame, this retrofit solution can save enterprises an average of $20,000 in direct investment costs. More importantly, it combines the advantages of fiber laser (good at high-speed cutting of thin plates) and flame cutting (strong in penetrating thick plates), achieving the optimal resource allocation of "one machine, two uses." For small factories and workshops with limited space and budget, this is the "fast track" to improving production capacity and competitiveness, ensuring the maximum return on investment.
Minimizing Production Downtime
We understand that the continuity of production is crucial. Thanks to the modular design and standardized processes, the entire retrofit cycle is strictly controlled within one week. This solution does not require complex reinstallation of the machine tool or axis alignment, greatly simplifying the installation process and minimizing interference with your daily production operations, ensuring a smooth and rapid transition to the new production capacity.
Costs and Systems Required for Retrofitting
The system + frame includes the electrical control cabinet (with laser cutting control system), control cabinet, cutting head, Z-axis slide table, pneumatic module, and beam.
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Power |
System & Frame Amounts |
Laser Source & Water Chiller Amounts |
Total Amounts |
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6000W |
～19680$ |
～8434$ |
～28114$ |
|
12000W |
～21086$ |
～12651$ |
～33737$ |
|
20000W |
～22491$ |
～23194$ |
～45685$ |
|
30000W |
～25303$ |
～37954$ |
～63257$ |
Recommended Laser Cutting Control Systems
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6000W: XC3000S system (laser & flame)
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12000W: XC3000 system (laser & flame)
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12000W: 20000W, 30000W: XC6000 system (laser)
Recommended Cutting Heads
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6000W: BM06K cutting head (laser & flame)
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20000W: BS20K-CAT cutting head (laser)
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30000W: BS30K-CAT cutting head (laser)
Recommended Laser Sources
Recommended Chillers
Special Note: Only the XC3000 series systems and non-CAT series cutting heads support dual use of fiber cutting heads and flame cutting heads.
Optional Materials: One-year consumables package、Tool kit、Voltage stabilizer、Air compressor、Integrator、Clean cabinet
Conclusion
The transition from plasma to fiber is not just a simple equipment update but a strategic transformation aimed at enhancing core manufacturing capabilities. Our solution aims to enable small and medium-sized factories to unlock and gain the multiple benefits of high precision, high efficiency, and dual-function flexibility with a limited investment. In summary, the value proposition of this solution is clear and powerful: it brings a series of significant benefits such as saving funds, improving performance, and expanding functions to enterprises through an efficient and controllable process.
Frequently Asked Questions (FAQ)
Q1: Is the strength and precision of my existing old frame (gantry) sufficient to support the new laser system? Will aging or wear affect the final cutting quality?
A: This is a crucial question. Before the project starts, our technical team will conduct a comprehensive assessment of your existing equipment, including the structural rigidity of the frame, deformation conditions, and the straightness and parallelism of the rails. Our customized laser beam has been designed to balance lightness and high rigidity, and its load on the frame is much lower than many traditional designs. If the assessment finds problems with the basic structure, we will make professional reinforcement or calibration recommendations to ensure that it meets the high-precision standards required for fiber laser cutting.
Q2: How can the new laser gantry accurately match my existing rails and racks of different brands or models?
A: This is the core advantage of our "customized" solution. Before manufacturing the new laser gantry, we will guide you to accurately measure key data, especially the center distance between the two Y-axis tracks and the modulus (M value) of the Y-axis rack. With our extensive experience database and flexible design capabilities, we can manufacture interfaces and transmission systems that perfectly match the vast majority of mainstream brand equipment on the market, ensuring seamless mechanical integration.
Q3: The optical fiber cable looks very delicate. How can it be protected in a factory environment to avoid damage during the gantry's reciprocating motion?
A: We have standardized professional protection measures for this. The optical fiber cable will be properly housed in a dedicated high-flexibility drag chain, with the bending radius of the drag chain designed strictly according to the safety standards of the optical fiber. At the same time, at the interfaces at both ends of the drag chain, we will also install stress-relief devices to prevent the optical fiber from being damaged due to pulling or bending during long-term motion, ensuring its long-term stable operation.
Q4: Both the laser and the laser head require water cooling. Does my factory need to undertake complex water system modifications for this?
A: No. Our solution will provide you with an independent industrial chiller that matches the power of the laser. This chiller has its own circulation system, and you only need to provide it with power and inject the specified amount of pure water. It will provide constant temperature cooling for both the laser and the laser head through two independent circulation water paths. The entire system is simple and efficient, and there is no need to modify the factory's water system.
Q5: After the retrofit, do I need to learn a completely new and complex software system? Is the training cost for operators high?
A: We usually equip the industry-wide widely used and intuitive cutting software (such as CypCut). Its interface is friendly, and its logic is clear, seamlessly compatible with CAD drawing software and dedicated nesting software. We will provide comprehensive online or on-site training, and usually, experienced operators can master it proficiently within 1-2 days. Our goal is to allow you to quickly start production with the lowest learning cost.
Q6: The radiation safety level of fiber laser is very high. How can the safety of operators be ensured?
A: Safety is the top priority. First, we will install laser protective covers or curtains that meet safety standards on the equipment to block laser reflections. Secondly, we will provide professional laser safety training for your operators and equip them with laser protective glasses that meet standards. We strongly recommend that customers designate a special laser operation area for the equipment and set up safety warning signs.
Q7: Are the maintenance costs high in the later stage? For example, what about the replacement frequency and cost of consumables such as laser head lenses and nozzles?
A: Fiber lasers themselves are maintenance-free, and the core components have a very long lifespan. The main daily maintenance focuses on the consumables of the cutting head, including protective lenses, nozzles, and ceramic rings. The lifespan of these consumables is directly related to the material you are cutting, its thickness, and the purity of the gas used. At the same time, our website also provides high-quality universal consumables, which are not only reasonably priced but also readily available in the market. Compared with the electrodes, nozzles, and other consumables of plasma cutting, the long-term overall operating cost of fiber laser is usually more advantageous.
