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17.Wildcard Week

Summary

In our laboratory, we have a large industrial metal-cutting machine capable of cutting steel up to 30 mm thick. This week, I planned to work with this machine to fabricate a stronger and more durable mechanical part for my project.

Leapion Economical Metal Laser Cutting Machine – Specifications and Safety

Machine Characteristics

The metal-cutting machine in our laboratory is a high-power industrial fiber laser cutter designed for precise cutting of thick metal sheets. Key characteristics:

  • Laser Type: Industrial fiber laser

  • Cutting Capacity: Up to 30 mm steel

  • Working Area: Large-format bed suitable for big mechanical parts

  • Cooling System: Integrated industrial chiller

  • Exhaust System: Powerful ventilation hood for smoke extraction

  • Control System: Touchscreen CNC panel with real-time monitoring

  • Accuracy: High precision suitable for robotics, mechanical frames, and structural components

  • Supported Materials: Steel, stainless steel, aluminum, and other metal alloys

This machine is ideal for fabricating strong and durable mechanical parts for my delivery robot.

Safety Procedures

Working with a high-power laser cutter requires strict safety compliance. Before operating the machine, I followed these rules:

1. Personal Safety

  • Always wear protective laser-safe glasses.

  • Wear heat-resistant gloves when handling freshly cut metal.

  • Ensure no flammable materials are near the working area.

2. Machine Setup Safety

  • Check that the metal sheet is properly fixed on the cutting bed.

  • Verify correct focus, power settings, and cutting speed.

  • Make sure the ventilation hood is turned on before starting the cut.

  • Inspect the cooling system and ensure good water circulation.

3. During Operation

  • Never place hands inside the machine while the laser is running.

  • Monitor the cutting process from the control screen.

  • Ensure emergency stop button is accessible at all times.

4. Post-Operation

  • Wait until the metal cools before touching it.

  • Clean the cutting area and remove metal scraps.

  • Turn off the laser source, CNC control, and ventilation system.

3D Modeling and File Export

To prepare a design for laser cutting, I first created a new sketch in Fusion 360. I selected a planar face (XY plane) and imported my reference image. Then I traced the outline using the sketch tools and made sure the profile was fully closed. After finishing the sketch, I exported it as a DXF file, which is the format required for laser cutting.

In this image, I open Fusion 360 and select File → New Design to start a new project.

Here, I save the new design by entering a project name and choosing its location in my Fusion cloud workspace.

In this step, I select a sketch plane (XY, XZ, or YZ) to begin drawing the 2D sketch.

This image shows how I import a PNG reference (the map of Kazakhstan) into the sketch using Insert → Canvas.

After importing, I position, scale, and align the reference image properly on the sketch plane.

Here, I manually trace the contour of Kazakhstan using lines and splines to create a closed sketch profile.

In this step, I extrude the traced profile by 2 mm to generate a 3D solid model.

This image shows the process of exporting the sketch using Right-click → Export DXF, preparing it for CNC or laser cutting.

In the final image, I give the DXF file a name and save it locally on my computer.

Preparation for Cutting and Laser Cutting Process

1. Industrial Water Chiller (CWFL-3000)

This machine is a water-cooling system for the fiber laser source. During metal cutting, the laser generates a very high amount of heat, and the chiller keeps the laser module at a stable operating temperature.

Functions:

  • Maintains laser temperature (usually around 23–25°C)

  • Prevents overheating of the laser

  • Ensures stable cutting quality

  • Increases laser lifespan

Without the chiller, the laser could overheat and shut down or get damaged.

2. High-Pressure Gas Cylinder (Air / Oxygen / Nitrogen)

This cylinder provides assist gas used during metal cutting.

Depending on the material and thickness, different gases are used:

  • Oxygen → for cutting carbon steel (helps with oxidation, faster cut)

  • Nitrogen → for stainless steel, aluminum (clean cut, no oxidation)

  • Compressed Air → for general purpose cutting

Why assist gas is important:

  • Blows molten metal out of the cut

  • Improves cutting speed

  • Prevents burn marks

  • Makes edges cleaner

  • Helps the laser focus remain stable

The gas works together with the laser head to achieve a precise cut.

Machine Control Panel

This is the main control panel of the industrial metal laser cutter. Here I can upload the DXF file, adjust laser parameters, set the cutting speed, focus height, and start or stop the cutting process. The emergency stop button is also located here for safety.

Laser Cutting Head & Metal Sheet

This photo shows the laser cutting head positioned above the metal sheet. The laser head automatically adjusts focus and follows the toolpath generated from the DXF file. The metal sheet is placed on a special support bed designed to handle high temperatures and avoid reflections during cutting.

In this step, I loaded my exported DXF file (Kazakhstan outline) into the laser cutting machine’s software. I selected the file, checked its properties, and prepared it for generating the toolpath.

After importing, I positioned the DXF geometry on the workspace area. The software displayed the vector toolpath in green, allowing me to visually confirm the size, origin point, and cutting order before starting the laser job.

First, I used the framing/outline tool of the laser cutter. The machine moved along the outer contour of my design without turning on the laser, allowing me to check that the material was correctly positioned on the bed. This step is important to make sure the sheet is aligned properly and that there will be no collisions or cutting errors.

After confirming that everything was correct, I pressed the Start button to begin the actual cutting process.

The laser machine has a slag tray where all melted metal and debris fall during cutting. After finishing the job, I used the metal scraper tool to pull out the tray and clean the remaining slag. This is an important maintenance step to keep the laser cutter working safely and efficiently.

Here is the final metal piece I cut using the fiber laser machine. The outline of Kazakhstan was successfully cut from a steel sheet. Some edges show burn marks because I used a higher power setting, but the overall shape came out correctly.

After the cutting was finished, I manually cleaned the edges using sandpaper. This removed the sharp edges, burn marks, and small residues left from the laser cutting process, making the final part smooth and safe to handle.

Final Result

Here is the final metal piece after laser cutting and manual post-processing. I cleaned the edges with sandpaper, removed burn marks, and smoothed the surface. The outline of Kazakhstan came out clean and well-defined.

Conclusion

This week I learned how to work with a professional industrial metal laser cutter. I went through the full workflow — from creating a 3D model in Fusion 360, exporting a DXF file, preparing the machine, setting the cutting parameters, and safely performing the cut. I also learned how the chiller, air assist, and exhaust system work together to support the laser.

After cutting, I manually cleaned and finished the metal piece using sandpaper. This assignment helped me better understand machine preparation, material behavior during cutting, and post-processing techniques.

Week files

File for cutting