Breakthroughs in Cutting Systems Create New Opportunities
Metal cutting systems deliver precise cuts, cut down on downstream processes, and assist in overcoming skilled labor shortages. The post Breakthroughs in Cutting Systems Create New Opportunities appeared first on Fabricating & Metalworking.
With their immense power systems, the implementation of automated material handling and technological advances such as AI, laser, plasma, oxyfuel, and waterjet cutting systems are reshaping the metal fabrication process. The advances position your shop to creatively and cost-effectively fabricate products that surpass customer requirements — today and in the future.
Autonomous Features Deliver High-speed, Continuous Operation
AMADA AMERICA, INC.’s (Buena Park, CA) REGIUS AJe Series combines the world’s fastest 3-axis linear drive system with a variety of autonomous features to ensure high-speed, continuous operation. The 3-axis linear drive system on the REGIUS softens the ramp up and ramp down traverse speeds to achieve high-speed, high-precision laser cutting. The linear drive generates 5g’s of acceleration and reaches traverse speeds of 13,300 inches per minute, reducing nest times by 15% compared to AMADA’s previous linear-driven machine.
The Laser Integration System (LIS) in the REGIUS consists of a variety of features to significantly reduce setup time and maximize quality. By autonomously monitoring for nozzle condition, pierce penetration, tip ups, and debris on the protection glass, the REGIUS can seamlessly navigate production issues that may disrupt laser cutting.
This innovative fiber laser series utilizes AMADA’s patented ENSIS technology that’s engineered specifically for manufactures that laser cut thin-to-thick materials. The line up for the REGIUS
series consists of the 6 kW with one module, 9 kW with three 3 kW modules, and 12 kW with three 4 kW modules.
The AMNC 4ie control is a large touchscreen monitor that allows users to easily see information and load programs based on file names. Thumbnail views of parts or nests provide for quick and easy identification to ensure editing of a program on the shop floor is fast and efficient. Facial recognition provides quick access to the operator’s customized control interface. Auto remnant nesting automatically places parts for maximum material utilization. Another advantage is that the surface treatment cut utilizes the irradiation of the laser to clean the material’s surface to improve cut quality.
Waterjet Series Processes a Range of Cutting Needs and Materials
Flex Machine Tools (Wapakoneta, OH) an American manufacturer and leading provider of machine tool solutions worldwide for metal fabrication operations and more, offers the FlexJet Waterjet Series with IGEMS CNC control, CAD/CAM software and hardware.
Known for its precision and versatility, the FlexJet Series features enhanced capabilities due to IGEMS’ software and hardware such as the advanced Tilter 5-axis waterjet cutting head, Snapper camera for optimal positioning, Rounder kinematic compensation tool, and Straighter perpendicular angle tool. These capabilities are designed to cater to the intricate needs of diverse materials and cutting requirements, ensuring unparalleled accuracy and efficiency in waterjet cutting processes. Additionally, the FlexJet is equipped with IGEMS’ HMI and Beckhoff’s industrial PC. This integration results in a significant leap in operational control and user experience, offering intuitive interfaces and robust performance that redefine industry standards.
FlexJet waterjets are designed to tackle intricate jobs effortlessly with a user-friendly design that prioritizes workflow, increases productivity, and delivers exceptional cutting power. Engineered and built in the USA, FlexJet waterjets are reliable for the most demanding cutting applications. Flex can customize waterjet solutions to match application requirements and provide stellar service and 24/7 remote response. Flex service technicians are located throughout North America.
https://flexmachinetools.com/waterjet/#Options
High Speed and Powerful Laser Cutting Machine
Machitech Automation’s (Saint-Marc-des-Carrieres, QC, Canada) new Fiber PRIME S Laser Cutting Machine sets a new standard in advanced cutting technology by combining high-speed 4G acceleration with high-power performance (12 kW to 60 kW) for cutting mild steel up to 4” thick. Fabricators and manufacturers can count on a laser cutting machine that delivers 24/7 reliable and efficient operation, provides rapid processing high-end performance for a range of heavy-duty applications, and comes with readily available customer service and support.
The Fiber PRIME S includes an exclusive Precitec Cutting Head. Built for high power applications, the Precitec head provides integrated gas mixing and focused compensation. It also features an optional bevel head, enabling the creation of complex bevel cuts. It also integrates an intelligent, intuitive and easy-to-use large screen CNC controller. Lantek Expert Cut Nesting Software combines advanced nesting and optimized cutting paths. An innovative modular frame addresses concerns for high-power cutting.
New Plasma Cutting Systems
Thermal Dynamics, an ESAB (North Bethesda, MD) brand, offers the Cutmaster® 50+ and Cutmaster 70+ manual plasma cutting systems. Cutmaster 50+ has a recommended pierce and cut capacity of 5/8” and severs metal up to 1-¼” thick. It has a rated cutting output of 50A at 60% duty cycle and weighs 35.3 lbs. The Cutmaster 70+ has a recommended pierce and cut capacity of ¾” and severs metal up to 1-½”. It has a rated cutting output of 70A at 60% duty cycle and weighs 35.3 lbs. Both machines are available in 110V – 240V 1ph and 480V 3ph primary power versions and come with an SL60 1Torch
, long-life Black Series consumables and a 15’ cable.
“These machines also offer a built-in 14-pin CPC port for easy CNC mechanization,” said Jay Misas, senior product manager, ESAB. “Smaller fabricators have told us that they want the flexibility to switch between manual and mechanized cutting to maximize utilization of their machines.”
With the 4.3” TFT LCD display, Cutmaster users can access, set and see such features as normal and grate cutting mode and 2T (standard) or 4T (“trigger latch”) mode. The 4T mode allows the operator to press and release the trigger and cut without holding the trigger, reducing hand fatigue on long cuts. The torch also features a “double-tap” trigger; tapping the trigger twice shuts the gas solenoid valve, extending the cutting time when using small portable cylinders of compressed air or nitrogen.
The Cutmaster+ systems feature IP23S housing, which handle rugged environments, making the machines suitable for light fabrication, industrial production and manufacturing, repair/maintenance and more.
Plate Processing Combined with Automated Material Handling
Tecoi USA’s (Longview, TX) new plate processing machines integrate large format thermal cutting with machining. Then, by combining automated material handling, manufacturers and fabricators benefit from a total system solution for increased productivity.
Designed for heavy-duty thermal cutting applications, Tecoi’s Thor® (Tecoi Hyper Operative Range) plate processing machine integrates plasma cutting and a beveling system, and oxyfuel cutting with an optional auxiliary tube and profile lathe. Thor also integrates mechanical cutting with the capability to manufacture parts using multiple operations, including milling, drilling, tapping, countersinking, marking, etc.
Tecoi’s LS Series Laser & Drilling Machine incorporates the choice of either one or two drilling heads, maximizing its large dimension laser processing cutting station capability. Each drill head includes up to 6 tools, with 22 hp, 4,000 rpm machining power per head, up to 22 mm drilling power and M16 (5/8”) tapping power, and a tooling change capability that can be accomplished in as fast as 0.8 seconds. Options include a Twin-Disk double-head cutting technology, a double core fiber system for thick and thin plate, and automatic beveling. Driltec Plus combines the latest laser processing technology (for cutting areas from 8′-x-20′ to as large as 20′-x-230′) with drilling and tapping.
For a total solution, Tecoi’s Stocktec system adds automated plate storage and processing, increasing overall productivity by reducing operation time and expanding storage capacity. The independent tray system stores and dispenses materials immediately based on production needs. Stocktec works well with all Tecoi large format plate processing machines, as well as almost any plate processing system. It can be integrated with up to 10 cutting machines or function as a standalone storage system.
Utilize AI to Improve Laser Cutting Edges
TRUMPF Inc. (Farmington, CT) offers the new “Cutting Assistant” application, which employs artificial intelligence (AI) to help users improve the quality of laser-cut edges. Production employees just take a picture of their component’s cut edge with a hand scanner. Then, the solution assesses the edge quality, evaluating it using objective criteria such as burr formation. With this information, the Cutting Assistant’s optimization algorithm suggests improved parameters for the cutting process. Then the machine cuts the sheet metal once more. If the part quality still does not meet expectations, the user has the option to repeat the process. This solution is available for all TruLaser series laser-cutting machines purchased as of May 2025, which feature a power output of 6 kW or higher.
“The Cutting Assistant is a great example of how AI-enabled tools can help overcome problems related to the skilled worker shortage and also saves time and money,” said Grant Fergusson, TRUMPF Inc.’s TruLaser 2D laser cutting product manager. “When it comes to productivity, this application creates a competitive edge for fabricators.”
When laser cutting, fabricators can find it challenging to determine the correct parameters to use for their material grades. Materials that are not optimized for laser cutting often produce edges with wide variations in cut quality, forcing production employees to constantly change the technology parameters. This involves adjusting each individual parameter one by one — a process which demands a lot of time and employee experience. This presents a challenge for many companies, especially those with inexperienced workers in production positions. By integrating the Cutting Assistant into the machine software, optimized parameters can be transferred seamlessly into the software without the need for programming.
In the future, data from applications in the field will also be incorporated into the Cutting Assistant solution. This will enable faster and more reliable results because the self-learning system will continuously improve. TRUMPF ensures that the algorithm does not distribute the user’s expertise.
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