Laser Cutting Design Guide
We review your material, sheet thickness, geometry, edge requirements and production quantity to help determine a suitable cutting approach for your project.
Get the Guide With Your QuotePrecision Laser Cutting for Custom Sheet Metal Parts
BoValley provides custom laser cutting services for sheet metal components with defined profiles, holes, slots and intricate contours. Laser cutting is well suited to flat-pattern parts used in enclosures, brackets, panels and fabricated assemblies.
Project Review
- Flat Pattern Review
- Sheet Grade and Thickness
- Finish and Edge Requirements
- Inspection Planning
- Part Geometry
- Flat profiles & openings
- Cut Planning
- Edge & thickness review
- Stock Type
- Sheet metal
Overview
What is Laser Cutting?
Laser cutting uses a focused laser beam to cut material along a programmed path. It is suitable for producing external profiles, internal cutouts, mounting holes and detailed two-dimensional patterns.
It can reduce the need for dedicated profile-cutting tools and is useful for prototypes, design iterations and suitable production batches.
Cut quality depends on material grade, thickness, laser equipment, feature geometry and specified edge conditions. Parts requiring tight tolerances or additional forming should be reviewed as a complete design.
Laser Cutting Capabilities
Review the sheet grade and thickness, smallest openings, edge requirements and spacing between features. Share the flat pattern and note any downstream forming.
Cutting Process
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
Materials
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
Sheet Thickness
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
Part Geometry
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
Dimensional Tolerance
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
Edge Condition
- Select suitable laser systems based on material, thickness, and geometry.
- Evaluate material grades, reflectivity, coatings, and equipment limits.
- Define dimensional tolerances, minimum features, and acceptable burr levels.
- Optimize part nesting and setup requirements to manage manufacturing costs.
MaterialsMaterials
Laser Cutting Materials
Material selection depends on part function, thickness, corrosion requirements, and the downstream manufacturing process.
- Aluminum 5052
- Aluminum 6061
- Stainless Steel 304
- Stainless Steel 316
- Cold-Rolled Steel
- Galvanized Steel
- Sheet thickness
- Cut-edge condition
- Heat tint and oxide
- Feature spacing
- Sheet grade and temper
- Corrosion exposure
- Surface appearance
- Formability
- Galvanic compatibility
- Part stiffness
- Visible face protection
- Coating adhesion
- Deburring
- Edge condition
- Hardware compatibility
- Fastener material
- Weldability
- Finish thickness
Surface Finish Options
Choose materials and finishes based on your part's mechanical properties, operating environment, appearance, and application requirements.
| Finish | Description |
|---|---|
| Deburred | Remove sharp edges to meet handling and assembly requirements. |
| Brushed or grained | Specify the visible face and grain direction for suitable materials. |
| Protective coating | Select a coating for the substrate and environment. Specify color, texture, and masking where needed. |
The Process
How Does Laser Cutting Work?
Use the flat pattern to program the cut path. A focused laser and assist gas cut the sheet, following the outside profile and internal features. Inspect critical holes and edges, then deburr or prepare the parts for forming as specified.
The advantages
- Detailed Profiles:• Create complex outlines, cutouts and slots from digital designs.
- Flexible Feature Layouts:• Support a wide variety of hole patterns and two-dimensional geometries.
- Non-Contact Cutting:• Laser cutting does not require a profile-cutting tool to contact the sheet.
The challenges
- Nesting Opportunities:• Part layouts can be planned to improve material utilization.
- Design Iteration:• Suitable for updating flat patterns without dedicated profile tooling.
QualityLaser-Cut Parts for Different Applications
The examples below show where this process may fit. Material, geometry, and the intended use determine the right approach for each part.
Brackets & Mounting Plates
Mounting features, slots, and custom profiles.
Construction
Cutouts and openings for functional components.
Flat Components
Custom outlines for mechanical and industrial parts.
Prototype Sheet Metal Parts
Design validation and early-stage fabrication.
Electrical Enclosures & Control Panels
Cut control openings, vent slots, and mounting holes from flat patterns.
Automotive & Transportation
Produce selected panel blanks, mounting plates, and brackets for development.
| Types of Parts | Function |
|---|---|
| Flat mounting plates | Cut holes and profiles for installation hardware. |
| Enclosure blanks | Prepare flat patterns for forming and joining. |
| Vent and control panels | Create slots and openings for airflow or component access. |
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