While laser cutting demonstrates advantages over other forms of cutting, there are also limitations to the process, including:
- The range of suitable materials
- Inconsistent production rate
- Metal hardening
- Higher energy and power consumption
- Higher equipment costs
As indicated in previous sections, laser cutting is suitable for a wide range of metals and non-metals. However, the material being cut and its properties often limits the suitability of some cutting mechanisms, assist gases, and laser types. Additionally, the material thickness plays a significant factor in the determination of the optimal laser power, assist gas pressure, and focal position for a laser cutting application. Varying materials or varying thicknesses within a single material also necessitate adjustments to the cut speed and depth throughout the cutting process. These adjustments create inconsistencies in production time, as well as increase the turnaround time, especially in large production runs.
One advantage of the laser cutting is the production of high-quality cuts which generally do not require extensive secondary cleaning, treating, or finishing. While in some respect this is advantageous, the resultant work hardening of the laser cut edges may be problematic for some applications. For example, parts requiring further processing, such as powder coating or painting, will first need surface treatment following the laser cutting process before receiving the necessary coating or paint. The addition of this step increases both the turnaround time and total processing costs.
While laser cutting can have lower maintenance and material costs over time, for some manufacturing applications, it may be more cost-effective to use other cutting processes. For example, while both metal and non-metal materials can be laser cut, laser cutting plastic causes the emission of potentially harmful and toxic gases. These emissions necessitate airpollution control equipment, increasing the necessary equipment costs. For manufacturers and job shops starting up, although replacement and maintenance parts are relatively inexpensive, the initial investment in laser cutting equipment also tends to be much higher compared to more conventional cutting processes. Additionally, laser cutting equipment typically consumes more power and energy than other cutting processes, leading to further increases in operating costs. Altogether, the high initial equipment and operating costs may make laser cutting unsuitable for low budget operations.
