A TECHNICAL SEMINAR ON

CO2 LASER CUTTING

A Technical Seminar report submitted to
Jawaharlal Nehru Technological University, Hyderabad
in partial fulfilment of the requirements for the award of the degree
of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted by
S RAKESH 21WJ5A0381

DEPARTMENT OF MECHANICAL ENGINEERING

GURUNANAK INSTITUTIONS TECHNICAL CAMPUS (AUTONOMOUS)
(Affiliated to JNTUH, Hyderabad, Approved by AICTE, New Delhi)
Ibrahimpatnam, Ranga Reddy District -501506
Telangana, India.
2023-2024
 CERTIFICATE

This is to certify that the Technical Seminar report entitled “CO2 Laser Cutting” is being
submitted by Mr. S RAKESH (21WJ5A0381) in partial fulfilment for the award of the Degree
of Bachelor of Technology in Mechanical Engineering to the Jawaharlal Nehru Technology
University, Hyderabad is a record of bonafide work carried out by him under my guidance and
supervision.
The results embodied in this Technical Seminar report have not been submitted
to any other University or Institute for the award of any Degree or Diploma.

Technical Seminar Guide

Mr. B. Thirupathi
Mr. J. Kishore
Mr. G. Venkatesh

Head of the Department

(MECHANICAL ENGINEERING)
 ACKNOWLEDMENTS

I wish to express my sincere thanks to Dr H.S SAINI, Managing Director, Guru Nanak
Institutions and Dr KODUGANTI VENKATA RAO, Director, Guru Nanak Institutions Technical
Campus, School of Engineering and Technology, for providing us with all the necessary
facilities and their support.
I place on record, my sincere thanks to Dr A RAJKUMAR, Professors Dean and Head of
the Department, Mechanical Engineering for their whole-hearted co-operation, providing
excellent lab facility, constant encouragement and unfailing inspiration.
I would like to say sincere thanks to Mr. B THIRUPATHI, Assistant Professor, and
Department of Mechanical Engineering for Co-ordinating Projects.
On a more personal note, I thank our BELOVED PARENTS and FRIENDS for their moral
support during the course of our project.

S RAKESH
21WJ5A0381
CONTENTS PAGE NO.

Chapter-1: Introduction 1-2

Chapter-2: History 3-4
Chapter-3: Benefits 5-6
Chapter-4: Limitations 7-8
Chapter-5: Applications 9-10
Chapter-7: Future scope 11-12
Chapter-8: Conclusion 13
 Abstract
Laser cutting is single of the furthermost extensively utilized thermal power process-based
non-contact types for cutting of materials, like titanium, stainless steel, aluminium and alloys
of aluminium, furthermore for non-metallic materials for example wood, glass, plastics,
ceramics, and composites utilized in various fabricating industries. This work enquires the
application of the CO2 laser cutting process to thermoplastic polymers, metal sheet
cutting, polypropylene (PP), polycarbonate (PC) in diverse thicknesses varieties. The objective
of the present study is to investigate the laser cutting parameter standards reported in
different researches to understood how to exploit the material exclusion rate while
concurrently allowing for practical process constraints associated with dross formation, kerf
width, perpendicularity deviance, surface roughness, and severance energy. This paper
evaluates the study effort conceded out until now in the precinct of Laser cutting of different
materials and shapes. It accounts for the experimental and theoretic studies of Laser cutting
to end the process enactment. To resolve the problem of optimum laser beam cutting,
backgrounds of many methods have been critically examined by taking account different
models of optimization. The work also targets studying the meting out parameters, such as
scanning speed, laser power, pulsing frequency, and gas pressure, for the laser cutting. Further
the aim of this study is to make the products profitably by using FEA, software nesting and
quality management effectively, which helps to maximize availability by minimizing the
equipment downtime caused by unnecessary stoppages.
 Chapter 1
Introduction

Laser, which is stands for Light Amplification by Stimulated Emission of radiation, is an

electrical-optical device that produces coherent radiation. Simply put, a laser is a device that
creates and amplifies a narrow, intense beam of coherent light. Nowadays, laser is widely
applied in today’s industry. Lasers are widely used in industry for cutting and boring metals
and other materials, in medicine for surgery, and in communications, scientific research, and
holography. They are an integral part of such familiar devices as barcode scanners used in
supermarkets, scanners, laser printers, and compact disk players. One of the laser systems
that dominate the commercial laser industry is CO2 laser systems. It has its own strengths in
various cutting and marking applications.

A CO2 laser is a type of gas laser. In this device, electricity is run through a gas-filled tube,
producing light. The ends of the tube are mirrors; one of which is fully reflective and the other

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which lets some light through. The gas mixture is generally comprised of carbon dioxide,
nitrogen, hydrogen and helium. Light produced by CO2 lasers is invisible, falling in the far
infrared range of the light spectrum. When stimulated by electric current, nitrogen molecules
in the gas mixture become excited, meaning they gain energy. Nitrogen is used because it can
hold this excited state for long periods of time without discharging the energy in the form of
photons, or light. The high-energy vibrations of the nitrogen in turn excite the carbon dioxide
molecules. At this point, the laser achieves a state called population inversion, the point at
which a system has more excited particles than non-excited ones. For the laser to produce a
beam of light, the nitrogen atoms must lose their excited state by releasing energy in the form
of photons. This happens when the excited nitrogen atoms contact the very cold helium
atoms, which causes the nitrogen to release light. The light produced is very powerful
compared to normal light because the tube of gases is surrounded by mirrors, which reflect
most part of the light traveling through the tube. This reflection of light causes the light waves
being produced by the nitrogen to build in intensity. The light increases as it travels back and
forth through the tube, only coming out after becoming bright enough to pass through the
partially-reflective mirror.

Light from a CO2 laser is powerful enough to cut many materials, including cloth,
wood and paper; the most powerful CO2 lasers are used for machining steel and other metals.
Although the highest-powered CO2 lasers run over 1,000 W, those used for machining are
generally between 25 and 100 W; by comparison, laser pointers are a few thousandths of a
watt. Because it's in the infrared, it has a very long wavelength, around 10.6 micrometres; it
is much longer than visible light, which runs between about 450 and 700 nanometres. As
continuous lasers go, the CO2 type is the most powerful in production.

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 Chapter 2
History of CO2 Laser Cutting

The foundation of CO2 laser cutting can be traced back to 1917 when Albert Einstein, a
renowned physicist, proposed the concept of stimulated emission, a fundamental principle
underlying laser operation. In 1960, Theodore Maiman at Hughes Research Laboratory
successfully constructed the first working laser using a ruby crystal, marking a significant
milestone in laser technology.

Invention of CO2 Laser:

In 1964, Kumar Patel, a scientist at Bell Labs, made a breakthrough by developing the first
carbon dioxide (CO2) laser. This innovation brought about a revolution in laser cutting
technology, as CO2 lasers offered several advantages over the earlier ruby lasers, including
higher power output, greater efficiency, and lower operating costs.

Initial Applications and Commercialization:

In 1965, Western Electric, a subsidiary of AT&T, introduced the first production laser designed
for industrial applications. This laser was primarily used for drilling holes in diamond dies,
demonstrating the practical potential of laser cutting technology.

Following this, in 1967, Peter Houldcroft at The Welding Institute in Cambridge, England,
made a significant contribution by developing an oxygen-assisted CO2 laser cutting technique.
This innovation enabled the cutting of steel sheets up to 2.5 mm thick, paving the way for the
widespread adoption of CO2 laser cutting in various industries.

Industrial Adoption and Advancements:

Throughout the 1970s and 1980s, CO2 laser cutting technology witnessed rapid
advancements, with continuous improvements in laser power, beam quality, and control
systems. These advancements led to the expansion of CO2 laser cutting applications across
various industries, including automotive, aerospace, electronics, and medical device
manufacturing.

Today, CO2 laser cutting remains one of the most widely used industrial cutting technologies,
offering a combination of precision, versatility, and cost-effectiveness. It continues to play a
crucial role in various manufacturing processes, enabling the production of high-quality
components and products.

Here's a summary of the key milestones in the history of CO2 laser cutting:

1917: Albert Einstein proposes the concept of stimulated emission.

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1960: Theodore Maiman constructs the first working laser using a ruby crystal.

1964: Kumar Patel invents the first CO2 laser.

1965: Western Electric introduces the first production laser for industrial applications.

1967: Peter Houldcroft develops the oxygen-assisted CO2 laser cutting technique.

1970s-1980s: Continuous advancements in CO2 laser power, beam quality, and control
systems.

Present: CO2 laser cutting remains one of the most widely used industrial cutting
technologies.

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 Chapter 3
Benefits of CO2 Laser Cutting
• High precision: CO2 laser cutting can achieve accuracies of up to ±0.001 inches. This
makes it ideal for applications that require precise cuts, such as the manufacturing of
medical devices and electronic components.
CO2 laser cutting machine with high precision

• Versatility: CO2 laser cutting can be used to cut a wide variety of materials, including
metals, plastics, wood, and glass. This makes it a versatile tool that can be used for a
wide range of applications.
• Non-contact process: CO2 laser cutting is a non-contact process, which eliminates the
risk of distortion or damage to the workpiece. This is because the laser beam does not
physically touch the material being cut.
• Speed: CO2 laser cutting is a very fast process. It can cut through materials much
faster than traditional cutting methods, such as sawing or milling.
• Cleanliness: CO2 laser cutting produces clean and precise cut edges. This is because
the laser beam vaporizes the material being cut, leaving no residue or burrs behind.
• Automation capabilities: CO2 laser cutting machines can be automated, which makes
them ideal for high-volume production. This is because they can be programmed to
cut complex shapes and patterns with great accuracy and consistency.

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In addition to the benefits listed above, CO2 laser cutting is also a relatively safe and
environmentally friendly process. It does not produce any harmful fumes or emissions, and it
can be used to cut materials that are difficult or impossible to recycle.

Here are some specific examples of how CO2 laser cutting is used in different industries:

• Automotive industry: CO2 laser cutting is used to cut a variety of automotive

parts, such as body panels, exhaust systems, and interior trim.
• Aerospace industry: CO2 laser cutting is used to cut a variety of aerospace
components, such as aircraft parts, spacecraft panels, and rocket engine parts.
• Electronics industry: CO2 laser cutting is used to cut a variety of electronic
components, such as circuit boards, semiconductors, and display panels.
• Medical device industry: CO2 laser cutting is used to cut a variety of medical
devices, such as catheters, surgical instruments, and implants.

Overall, CO2 laser cutting is a powerful and versatile tool that has a wide range of benefits. It
is a valuable asset for many industries, and it is likely to continue to be used for many years
to come.

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 Chapter 4
Limitations of CO2 Laser Cutting

Despite its numerous advantages, CO2 laser cutting has certain limitations that need to be
considered when choosing this technology for a particular application.

1. Material Thickness Limitations CO2 laser cutting is generally limited to cutting

materials with a thickness of up to 1 inch or 25 mm. While this range covers a wide
variety of materials and applications, it may not be suitable for cutting thicker
materials that require higher power lasers, such as fiber lasers.

2. Heat-Affected Zone (HAZ) CO2 laser cutting produces a heat-affected zone (HAZ)
around the cut edge, which is an area of material that has been altered by the heat of
the laser beam. This HAZ can affect the material's properties, such as hardness and
corrosion resistance. The width of the HAZ depends on the material being cut and the
laser power settings, but it can be a concern for applications where material integrity
is crucial.

3. Fume Production Some materials, such as plastics and wood, can produce harmful
fumes when cut with a CO2 laser. These fumes can irritate the eyes and respiratory
system, and they can also be flammable. Proper ventilation and fume extraction
systems are essential to ensure a safe working environment.

4. Initial Investment and Operating Costs CO2 laser cutting machines typically have a
higher initial investment cost compared to other cutting methods, such as waterjet or
plasma cutting. Additionally, the operating costs of CO2 laser cutting, including laser
gas consumption and maintenance expenses, can be significant.

5. Beam Reflection and Eye Safety CO2 lasers emit infrared light, which is invisible to the
human eye. However, infrared light can be reflected off shiny surfaces, posing a risk
of eye damage. Proper safety measures, such as wearing protective eyewear and using
laser safety enclosures, are essential to prevent eye injuries.

6. Material Compatibility CO2 laser cutting is not suitable for all materials. Some
materials, such as copper and brass, reflect the laser beam, making them difficult to
cut accurately. Other materials, such as some ceramics and composites, may require
specific cutting parameters or post-processing to achieve desired results.

7. Edge Quality While CO2 laser cutting can produce clean and precise cut edges, the
quality of the edge can vary depending on the material being cut and the laser power
settings. For applications requiring extremely high edge quality, such as in the
electronics industry, additional processing steps may be necessary.

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 8. Maintenance Requirements CO2 laser cutting machines require regular maintenance
to ensure optimal performance and longevity. This maintenance includes cleaning
mirrors and lenses, replacing gas tubes, and performing alignment checks. Proper
maintenance can extend the lifespan of the machine and reduce downtime.

In summary, while CO2 laser cutting offers numerous advantages, it is essential to consider
its limitations when evaluating its suitability for a particular application. Material thickness,
heat-affected zone, fume production, initial investment and operating costs, beam reflection
and eye safety, material compatibility, edge quality, and maintenance requirements are all
factors that need to be carefully assessed. By understanding these limitations, users can make
informed decisions and ensure that CO2 laser cutting is the most appropriate technology for
their specific needs.

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 Chapter 5
Applications of CO2 Laser Cutting

CO2 laser cutting is a versatile and precise process that is used in a wide variety of applications
across divers as industries. Its ability to cut through a wide range of materials with high
precision and minimal heat damage makes it a valuable tool for manufacturing, prototyping,
and fabrication. Here are some of the key applications of CO2 laser cutting:

1. Automotive Industry: CO2 laser cutting is widely used in the automotive industry to
cut various components, including body panels, exhaust systems, interior trim, and
electrical components. The precision and speed of CO2 laser cutting make it ideal for
producing complex shapes and patterns with high accuracy.

2. Aerospace Industry: In the aerospace industry, CO2 laser cutting is used to cut a
variety of lightweight and high-performance materials, such as composites, aluminium
alloys, and titanium. It is employed to manufacture aircraft parts, spacecraft panels,
rocket engine components, and other critical aerospace structures.

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3. Electronics Industry: CO2 laser cutting plays a crucial role in the electronics industry
for cutting circuit boards, semiconductors, and display panels. The precise control and
non-contact nature of CO2 laser cutting ensure that delicate electronic components
are not damaged during the cutting process.

4. Device Industry: CO2 laser cutting is an essential tool in the medical device industry
for manufacturing catheters, surgical instruments, implants, and other medical
components. The ability to cut intricate shapes and maintain sterility makes CO2 laser
cutting ideal for producing precise and biocompatible medical devices.

5. Signage and Display Production: CO2 laser cutting is widely used in the signage and
display industry to create custom signage, promotional displays, and point-of-
purchase (POP) materials. It can cut through a variety of materials, such as acrylic,
wood, cardboard, and various plastics, making it versatile for creating different types
of signage and displays.

6. Packaging and Paper Converting: CO2 laser cutting is used in the packaging and paper
converting industry to cut and perforate paper, cardboard, and other packaging
materials. It can create intricate designs, score folds, and perforate openings, making
it ideal for producing custom packaging and labels.

7. Prototyping and Modelling: CO2 laser cutting is a valuable tool for rapid prototyping
and modelling in various industries, including product design, engineering, and
architecture. It allows for quick and precise creation of prototypes and models from a
variety of materials, enabling designers and engineers to visualize and test their
designs before committing to full-scale production.

8. Fabrication and Specialty Applications: CO2 laser cutting is also used in various
fabrication and specialty applications, such as jewellery making, textile cutting, and
leather cutting. Its ability to cut intricate shapes and patterns with high precision
makes it suitable for creating unique and personalized products in these industries.

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 Chapter 6
Future scope of CO2 Laser Cutting

CO2 laser cutting technology has been a staple in the manufacturing industry for decades,
and it is likely to continue to play a significant role in the future. Here are some of the key
trends and advancements that are shaping the future of CO2 laser cutting:

1. Increased Power and Efficiency: CO2 laser technology is constantly evolving, with
advancements in laser sources and beam control systems leading to higher power
output and improved efficiency. This means that CO2 laser cutting machines will be
able to cut thicker materials faster and with less energy consumption.

2. Automation and Integration: Automation and integration with other manufacturing

processes are becoming increasingly important in the laser cutting industry. This
includes the development of automated loading and unloading systems, as well as
integration with robotics and CNC (computer numerical control) machines.

3. Micro and Picosecond Laser Cutting: Micro and picosecond laser cutting technology
is emerging as a powerful tool for cutting extremely thin and delicate materials, such
as medical implants, electronics components, and micro-optical devices.

4. Hybrid Laser Cutting: Hybrid laser cutting combines two or more laser sources, such
as CO2 and fibre lasers, to achieve the best of both worlds. This allows for cutting a
wider range of materials with higher precision and speed.

5. Remote Monitoring and Diagnostics: Remote monitoring and diagnostics systems are
being developed to enable operators to track the performance of their laser cutting
machines in real-time and identify potential problems before they cause downtime.

6. 3D Laser Cutting: 3D laser cutting is becoming increasingly popular for cutting complex
shapes and structures in three dimensions. This technology is particularly useful for
the production of molds, prototypes, and customized products.

7. Adaptive Optics and Beam Shaping: Adaptive optics and beam shaping technologies
are being developed to improve the quality and focus of the laser beam, allowing for
more precise and consistent cutting results.

8. Environmentally Friendly Laser Gases: Research is underway to develop

environmentally friendly alternative laser gases to replace CO2, which is a greenhouse
gas. This could further reduce the environmental impact of CO2 laser cutting.

In addition to these technological advancements, the future of CO2 laser cutting is also being
driven by the growing demand for personalized and customized products, the need for
shorter production cycles, and the increasing adoption of digital manufacturing technologies.

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As these trends continue to develop, CO2 laser cutting is likely to remain a key technology in
the manufacturing industry for many years to come.

Overall, the future of CO2 laser cutting is bright. With continued advancements in technology,
increased automation, and a growing demand for precision cutting, CO2 laser cutting is well-
positioned to play an even more important role in the manufacturing industry in the years to
come.

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 Chapter 7
Conclusion

CO2 laser cutting technology has emerged as a powerful and versatile tool in the
manufacturing industry, offering a combination of precision, speed, and efficiency that has
transformed various production processes. Its ability to cut through a wide range of materials
with minimal heat damage has made it an indispensable tool in industries such as automotive,
aerospace, electronics, and medical devices.

The future of CO2 laser cutting is promising, with continuous advancements in laser
technology, automation, and integration with other manufacturing processes. The
development of higher power lasers, micro and picosecond cutting capabilities, and
environmentally friendly alternatives to CO2 gas further expands the potential of this
technology.

CO2 laser cutting is well-positioned to remain a critical technology in the manufacturing

industry for the foreseeable future, contributing to the production of high-quality, customized
products with shorter lead times and reduced environmental impact. Its adaptability,
precision, and versatility make it an invaluable tool for engineers, designers, and
manufacturers across diverse industries.

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