Material Processing: Laser Cut Vs CNC Router

Material processing is critical in manufacturing and fabrication. Two popular techniques, laser cutting and CNC routing, have revolutionized how we process materials. They offer unwavering accuracy, precision, and flexibility. From customized designs to complex shapes, these technologies meet the diverse needs of different manufacturing industries.

However, which method is better suited for your material processing needs? This article explores the key differences, advantages, and best use cases for laser cutting vs CNC routing. 

Material Processing with Laser Cutting

Laser cutting is an advanced noncontact manufacturing technology that processes material with high precision. It can cut, engrave, or etch materials to create intricate designs. Laser cutting works by directing a focused laser beam onto the workpiece surface. This action melts and burns the material along the cutting path. Material processing with laser cutting begins with creating the digital design using compatible software. You then generate the laser beam with a CO2, fiber, or Nd: YAG laser source. Focus the laser beam using lenses and move the beam head to get precise cuts and engravings. The beam interacts with the material as you use the assist gas to remove debris. 

Laser cutting is popular in modern manufacturing industries because of its ability to achieve tolerances as tight as +/- 0.001 inches. You can cut a wide range of materials, including metals, plastics, wood, and composites. This makes laser cutting useful when manufacturing automotive body panels, medical tools, and custom electronic enclosures.

Material Processing with CNC Routing

CNC routing is a subtractive manufacturing process that uses a high-speed rotating tool to shape a workpiece. You start CNC routing with a metal block and gradually remove excess material to get the final design. This technology is the go-to for many applications, including metal fabrication, aerospace part manufacturing, and woodworking. It is accurate and has the ability to cut several inches deep in a single pass. 

To process material with CNC routing, you must create a CAD design and convert it to a CNC-compatible G-code program. You then set up the material and clamp it to the worktable. Select the right tool and execute the operation. The program runs till the end to give the final part. CNC routing is fully automated and allows for customization. You can create one-off custom parts with ease.

Comparison of Laser Cutting and CNC Routing

Laser cutting and CNC routing are widely used in manufacturing. However, they differ in the way you use them for material processing. Let’s discuss how laser cutting and CNC routing handle material type, thickness, and complexity. 

Material Type

Material compatibility is a significant difference between laser cutting and CNC routing. Laser cutting is particularly effective for metals like carbon steel, stainless steel, aluminum, and copper. You can also use it to process nonmetals, including wood, plastics, and rubber. However, wood, plastics, composites, and soft metals are the most suitable materials for CNC routing. 

Material Thickness Handling

The material thickness handling capabilities of these techniques also differ. Laser cutting may come with some thickness limitations depending on the material type. This process works with aluminum and copper sheets that are 3mm thick or less. On the other hand, CNC routing can handle thicker materials efficiently. It cuts several inches deep. 

Design Complexity

Depending on design complexity, you can also differentiate between laser cutting and CNC routing. Laser cutting is precise for intricate and detailed geometry. It excels in 2D designs like jewelry making and decorative panels. In comparison, CNC routers are superior for 3D machining and deep milling. You can use it to create designs with pockets and recesses. 

Accuracy and Precision 

Laser cutting comes with unparalleled accuracy and precision. It machines parts with extremely tight tolerances. This can be attributed to this process’ focused laser beam and noncontact feature. However, CNC routing accuracy has slightly lower precision than lasers. In CNC routing, tool deflection can occur when applying too much force on thick materials. 

Edge Quality and Finishing 

The quality of the final cut can also serve as the basis for differentiating between laser cutting and CNC routing. Laser cutting produces clean, smooth edges with little to no need for post-processing. The gas assist used in this process helps to make cuts with no burrs. CNC routing may need further processing to get the desired finish. It produces tool marks and chipping that reduces quality.

Speed and Efficiency

You can also differentiate between laser cutting and CNC routing based on speed and efficiency. Laser cutting is fast especially for materials with thin to medium level thickness. The laser beam moves quickly and can cut intricate patterns in a single pass. In contrast, CNC routing can be slower for complicated designs. This is because the router bit must constantly contact the material for a cutting action. 

Cost

Cost and budget also matter when differentiating between laser cutting and CNC routing. Laser cutting can be expensive to install and carry out, especially for fiber lasers. It consumes high energy and requires assist gases. CNC routing investment costs are generally lower than laser cutting because energy consumption is moderate. However, you may incur higher maintenance expenses because of tool wear and replacement. 

Table 1: Comparison between laser cutting and CNC routing

Choosing the Right Technology for Your Needs

There is no straightforward approach when choosing the correct technique for your project. You have to consider factors like cost, material, and turnaround time. 

When to Choose Laser Cutting 

You should go for laser cutting if you need,

• High precision and intricate designs. 
• Clean and polished edges with minimal finishing.
• Working on materials with thin to medium thickness.
• Faster production for high-volume jobs.

When to Choose CNC Routing 

CNC routing is the best choice when,

• Cutting thick and solid materials.
• The project requires low equipment costs.
• Making stronger and more structural cuts.
• Working with soft materials that laser cutting may damage.

Conclusion

The choice between laser cutting and CNC routing for material processing depends on the specific requirements of your project. Both metal cutting techniques offer unique advantages and limitations. Consider the workpiece material and thickness level when choosing the ideal one for your project. You should also keep in mind design complexity, required tolerance limit, and cost. You can make more informed decisions by understanding the differences between laser cutting and CNC routing.