Longsheng

5. Practical Operational Recommendations
Before processing, 10×10 cm of samples were cut, the cutting surface was observed using a scanning electron microscope (SEM), and the impact resistance was tested according to ASTM D256. IPG Photonics' AMB series and other models with enclosed cutting chamber and negative pressure flue gas extraction ensure safe and accurate cutting.

Delrin (POM) - Selection of precision gears that are deformed to zero

For Delrin's Laser Cutting Application (POM) - Selection of Precision Gear Zero Deformation, the following are the key process parameters, industry cases and safety control points:

1. Accurate Cutting Core Parameters
Laser Type:

Fiber Laser (1064nm, Continuous Wave) or UV Laser (355nm, Cold Operation)

Recommended Power: 30-60W (too High Power Fluid Edge)

Gas Protection:

Natural Assist (Purity ≥99.9%), Air Pressure 0.8-1.2 bar

Heat Affected Zone (HAZ): ≤0.05mm (Measured ISO 286-2 H5 Tolerance)

Cutting Accuracy:

Tolerance: ±0.005mm (For surfaces between gears)

Slot Width: 0.02-0.05mm (UV Better)

2. Industry Application Case - Swiss ETA Sports Equipment Kit
Process Requirements:

Gear Groove: Module ≤0.3, Teeth Surface Roughness RA <0.8μm (DIN 3962)

No Post-treatment: Direct Cutting and Forming to Avoid Target Speed ​​and Damage

Equipment Configuration:

High Accuracy Battery Meter System (e.g. Scanlab Intelliscan), repeatability of ±1μm

Constant Temperature Cutting Room (23±0.5°C) Reduces Thermal Expansion of Material

3. Toxicity control (formaldehyde release)
Safety standard:

China: GB/T 18883 "Indoor air quality standard" Formaldehyde <0.05mg/m³

EU: EN 717-1 (E1 grade, formaldehyde emission ≤0.062mg/m³)

Protection measures:

Real-time monitoring: Install formaldehyde sensors (such as Honeywell HPMA115S0)

Exhaust system: wind speed ≥1.0m/s, activated carbon filtration (adsorption efficiency > 95%)

4. Process Optimization Comparison Table

ABS-Low-cost solution for automotive interior parts

In in-house manufacturing of automobiles, ABS is the preferred material for laser cutting due to its cost advantage. The following analysis analyzes its application points from the aspects of process, safety, material properties and verification.

1. Key parameters of low-cost cutting process

Prevent ABS paper twisted during cutting, preheat the laminate to 80°C and heat evenly. The 30WCo₂ laser (wavelength 10.6μm) was used to remove the slag at a speed of 800 mm/min and cooled it with 0.3-0.5 bar compressed air. According to the VDA 6.3 standard, the Burr height is controlled to be less than 0.1 mm through visual and touch detection and the cutting width is maintained between 0.2-0.3 mm, which is suitable for internal part structures.

2. Industry compliance and toxicity control

ABS cutting styrene, the work area must be styrene concentration ≤20ppm according to EPA 40 CFR Part 63. It can be monitored using PID sensors such as RAE Systems Multirae Lite. Smoke purification adopts two-stage filtration of metal filter and activated carbon. The removal rate of VOC exceeds 90%, and the exhaust speed is ≥0.8m/s, meeting the requirements of OSHA ventilation.

3. Limitations and alternatives to applied materials

ABS cannot pass ISO 10993-5 cytotoxicity test due to the release of trace amounts of styrene and acrylonitrile, and therefore cannot be used for medical use; its glass transition temperature is about 105°C and will deform after long-term use of 85°C. Polypropylene (PP) is a more economical alternative, with PP laser cutting power of 20-40W, grease-resistant, detergent, and 7-10 yuan cheaper per kilogram.

4. Process verification process for internal parts of automobile

Before mass production, the cutting process should be strictly verified, 5 sets of 100 mm samples should be made, and the dimensional tolerance (±0.1mm) should be detected according to VDA 6.3, and burrs should be detected. High temperature and humidity simulation tests were performed at 85°C for 240 hours to ensure warpage <0.5% (SAE J1889 standard). Cutting efficiency can be improved by using a Trumpf Trulaser 3030 such as an Optical Fly-Flight system.

Abdominal muscle cutting parts are strictly prohibited for medical useThe purpose of preventing inflammation caused by contact with human tissues. ABS combustion will release HCN and CO, and work locations should be equipped with Class B fire extinguishers, such as carbon dioxide, to prevent fire and explosions.
By reasonably controlling preheating, laser parameters and emissions, ABS can meet the low-cost quality generation inside the car. In practical applications, alternative materials (such as PP) should be selected according to the characteristics of the material to ensure production safety and product quality.

Polyethylene (HDPE) - Quick Drilling of Chemical Storage Tanks

High-speed cutting process: 8000mm/min 6bar air cooling technology
In view of the high efficiency opening requirements of thick-walled HDPE storage tanks, the CNC equipment has a linear cutting speed uses more than 8000mm/min, and uses 6 bar high-pressure compressed air for real-time cooling. More than 90% of the slag residues can be eliminated by a directional flow of air, while tool coating technology is optimized to extend the blade life by 3 times. The roughness of the cutting surface is stably controlled in RA3.2 μm, which meets the requirements of corrosion resistance and chemical storage tank sealing.

UL 2809 certified recycled HDPE intelligent processing solution
Purpose-made cutting parameters for eco-cycling polyethylene certified materials:

30%-50% recycled material ratio: dynamic adjustment of spindle speed (4000-6000rpm)

Glass fiber reinforced grinding: enable multi-angle layered cutting strategy

High elastic compounds: Activate vibration suppression compensation system
Through the real-time detection module of material density, the feed rate and cutting depth will be automatically matched to ensure that the strength of the processed surface of the recycled material reaches more than 95% of the raw material, avoiding the risk of interface stratification.

ASME B16.5 standard flange connection is precisely molded
Five-axis interlocking CNC system is used to achieve ultra-precise machining:

Laser profile scanning: predict and automatically compensate for tank surface errors

High frequency fine-tuning technology: control radial jump of tool <0.005mm

Online roundness detection: immediate feedback of egg data after processing each hole
Flange sealing surface flat error <0.08mm, and hole diameter tolerance is controlled within ±0.1mm, strictly comply with ANSI 150 lb flange assembly standards, and pass air tight test at once.

Functional module of intelligent tank conversion system
✅Adaptive material identification: infrared spectroscopy analysis of proportion of recyclable material components
✅Thermal deformation monitoring: distributed temperature sensor warning material softening
✅Safety interlocking mechanism: Automatic detection of residual pressure and chemicals in storage tanks

✅Process database: 200 HDPE grade processing parameters

Typical application scheme:

Emergency repair opening of acid and alkali storage tanks

Standardized interface upgrade of food-grade containers

Mass production of recycled plastic storage tanks

Renovation of safe pressure relief ports for hazardous chemical storage tanks

Using a modular tool system, a machine can complete 30 sets of DN80-DN400 standard interface processing per day, which increases efficiency by 400% and reduces labor costs by 70% compared to traditional processes.

PTFE (Teflon) - Cold cutting of 5G microwave equipment

Ultraviolet laser 355nm wavelength core technology
Use a short-pulse ultraviolet laser system (pulse width <15N), non-contact cold cutting is achieved through a wavelength of 355nm, the heat-affected area is <10μm, and the dielectric loss is strictly controlled below 0.0002 (IPC-4103 standard). For RF equipment for military communications, it is equipped with a high-precision grating standard positioning system to ensure processing accuracy of ±5μm (MIL-PRF-55342 Class 3).

Perfluorinated Toxic Gas Treatment Plan
Four-stage Filtration System: Activated Carbon HEPA Chemical ScrubbingPlasmaDecomposition

Negative Pressure Operating Room: Real-time Monitoring of PFOA/PFOS Concentration

Special Scrubber: 99.99% Fluoride Capture Efficiency

Nylon (PA) - Engine compartment pipe marking

Fiber laser 1064NM wavelength advantage
Compared with traditional CO₂ lasers, the absorption rate of nylon is increased by 300%, and a power combination of 45-55W is adopted:

0.2mm Depth control: pulse frequency 20-80kHz adjustable

Anti-carbonization process: Dual-zone cooling system maintains material temperature <180°C

Character definition: Line width accuracy ±0.05mm (IATF 16949 6.3.1)

Special requirements for the automotive industry
✅Micro value HV0.3 in marked areas retains ±5% of the original value
✅ Passed the 85°C/85% RH wet cycle test
✅Silicone and fluoride-containing detergents are prohibited

PEI (ULTEM®) - Aerospace High Temperature Parts

NAS 411 certified cutting parameters

Key Points of Cost Control

1. The thickness of the raw material is preferably 1-3mm (material output increases by 40%)
2. Use nested typesetting software to reduce waste
3. Tool life monitoring (mandatory replacement every 500 meters)

Peeing - The King of Medical Implant Biocompatibility

ASTM F2026 standard laser cutting
Cell viability guarantee: pulse energy ≤0.8MJ, frequency 100kHz

Surface completion process:

EDM completion after laser cutting (RA ＜0.8μm)

Plasma activation treatment

Medical ethanol gradient cleaning

Special requirements for Class III medical equipment

• FDA PMA Process Execution Design Freeze Control
• Batch traceability system records laser parameter fluctuations
• Cleaning room standard: ISO Class 7 environment

Overview

In Plastic laser cutting, ten major materials, such as acrylic acid (PMMA), polycarbonate (PC), PTFE and PEEK, have become the first choice in the industry due to their unique physical properties and laser adaptability. By accurately matching laser wavelengths (e.g. UV, CO₂, fiber) and the thermal sensitivity of the material, combined with process optimization, such as nitrogen protection and exhaust gas filtration, it is possible to consider reducing accuracy (±5 μm) as well as safety and environmental protection (e.g., zero PFOA PFOA PFOA). Future technologies will focus on the development of composite laser sources and AI parameter adaptive systems, promote nano-level thermally affected area control in high-end applications, such as 5G communication devices and medical implants, and build new ecosystems for efficient and low-carbon precise processing through recycled material databases and digital process chains.

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