Is Laser Cutting Cheaper Than CNC

Laser cutting and CNC machining are precision-based subtractive manufacturing processes capable of fabricating parts with tight tolerance specifications. Both operations utilize CNC functionalities, allowing the automation of the process and enhancing their speed and accuracy. Consequently, one may wonder which is cheaper, particularly when budget is an important factor in determining what process suits your project.

So, is laser cutting cheaper than CNC?

This article answers the question while also providing you with a detailed overview of each manufacturing method, including its features, applications, pros, and cons. We also discussed cases where you should opt for laser cutting over CNC.

Is Laser Cutting Cheaper Than CNC?

The cost comparison between laser cutting and CNC machining largely depends on various factors like material, complexity of the design, volume of production, and precision requirements. In general, for thin materials and intricate designs, laser cutting is often more cost-effective due to increased speed, efficiency, and lower tooling costs. Laser cutting excels in accuracy and detail, especially for sheet metals, reducing material waste and setup time.

However, for thicker materials or parts requiring 3D shaping, CNC machining can be more economical. While it may have higher upfront costs for tooling and setup, CNC machines offer greater versatility in shaping complex geometries that laser cutting cannot achieve.

Therefore, laser cutting tends to be cheaper for simple, high-precision 2D cuts on thin materials, while CNC machining is more cost-efficient for thicker, more complex parts.

CNC Laser Cutting

CNC laser cutting is a manufacturing process that uses high-powered laser beams controlled by computer programs to cut, engrave, or etch materials with precision. The CNC laser cutter directs a focused laser at the material, which melts, burns, or evaporates it, resulting in clean, sharp cuts.

This method is ideal for creating intricate designs on thin materials such as metals, plastics, and wood. CNC laser cutting is widely used in industries that demand precision, accuracy, and efficiency in creating components and designs, particularly for sheet metals, prototypes, and custom parts.

Features  

CNC laser cutting offers exceptional accuracy, achieving tight tolerances and intricate details with minimal human intervention. Unlike many other subtractive manufacturing processes, laser cutting is non-contact. Therefore, there’s little to no mechanical stress on the material, reducing the chances of deformation or damage. CNC laser cutting is fast, automated, and suitable for large production runs. It minimizes material wastage as it only cuts based on what was pre-programmed.

The high precision is due to the laser’s thin focal point, which allows complex and delicate cuts. Moreover, it is a computer-controlled process, requiring minimal human intervention after programming the device. In addition, CNC laser cutting is highly versatile, accommodating a range of materials such as metals, plastics, and even non-metallic materials like wood or glass. However, the process is not palatable for cutting thicker metals. 

Applications  

CNC laser cutting offers applications across various industries. They include the following. 

• Automotive Industry: Cutting and engraving automotive parts, such as body panels, dashboard components, and trim panels. It also suits customizing car accessories, e.g., emblems.
• Aerospace Industry: Manufacturing precision parts and components for aircraft like winglets, fuselage, etc.
• Medical Devices: Cutting of medical implants, such as hip and knee replacements, surgical instruments and housing of medical devices.
• Electronics: Creating small, intricate parts like circuit boards, switches, casings, and connectors
• Signage and Display: Cutting and engraving acrylic, wood, or metal for custom signs, logos, and lettering.
• Jewelry and Fashion: Producing fine details for accessories and custom jewelry designs.

Pros  

The advantages of  CNC laser cutting include the following. 

• High cutting precision and accuracy.
• It's a non-contact process; therefore minimal material damage.
• Suitable for intricate and detailed designs.
• Quick processing speed and production efficiency.
• Capable of handling both small and large production volumes.

Cons  

The cons of CNC laser cutting include the following. 

• Not suitable for cutting thick materials.
• High initial setup and equipment costs
• It is restricted to 2D and flat material cuts.

CNC Machining

CNC machining is a subtractive manufacturing process where computer-controlled machines perform precise cutting operations on various materials.  It involves using a Computer Numerical Control (CNC) system to direct machine tools like mills, lathes, drills, and routers to produce complex and high-tolerance parts from solid blocks of material. These devices suit specific machining operations - milling, turning, drilling, and routing, respectively. 

However, some sophisticated CNC machining devices, such as 5-axis machining centers, offer vast capabilities. Such a machine can perform various machining operations. Regardless of the CNC machine you are using, the machining process is quick and excels in creating detailed and accurate components. 

Therefore, CNC machining services are one of the go-to operations for rapid prototyping and high-volume part fabrication. CNC machining is versatile and can work with a variety of materials, including metals, plastics, and composites, offering high precision and consistency across parts.

Features  

High precision, dimensional accuracy and repeatability are the hallmarks of all CNC machining services. The combination of these features makes CNC services one of the most common choices for fabricating components with complex geometries and tight tolerance specifications. A typical CNC machine consists of different cutting tools, allowing the machinist to perform various operations in a single setup. The device is highly automated, relying on minimal human interference, reducing manual labor and enhancing manufacturing speed and efficiency.

Applications  

CNC machining, like laser cutting, has applications in various industries. However, machining services are better suited for creating more rigid, structural, and thicker components. Below are some of its applications. 

• Aerospace Industry: Manufacturing critical components such as aircraft engine components (turbine blades and compressor vanes) and structural parts (wing ribs and fuselage frames).
• Automotive Industry: Producing engine components (engine blocks and cylinder heads), gearboxes and transmission parts, and custom fittings, such as intake manifolds and exhaust systems
• Medical Device Manufacturing: Creating precision parts for implants and surgical instruments, including medical device components like pacemaker housings and stent components. 
• Tool and Die Making: Fabricating tools, molds, and dies for other manufacturing processes.
• Electronics: Producing housings and enclosures for electronic devices. It also suits creating connectors, heat sinks, laptop housings, etc. 

Pros

The advantages of CNC machining include the following:

• High precision and accuracy in part fabrication.
• Capable of handling complex geometries and tight tolerances.
• Versatile with the ability to work with an extensive range of materials.
• Automated process reduces labor and minimize error.
• Suitable for both low and high-volume production.
• Consistent quality across large quantities of parts.
• Efficient for creating prototypes and custom parts.

Cons

The downsides to CNC machining are: 

• Initial setup and equipment costs are on the high side.
• Requires skilled operators and programming knowledge.
• Since it is a subtractive process, material wastage is almost impossible.

Why Opt for Laser Cutting Rather Than CNC?

While laser cutting and CNC machining services are excellent options for parts manufacturing, CNC is the better choice for the following reasons. 

Material Type and Thickness

The first criterion to consider when deciding which CNC operation best suits your manufacturing project between laser cutting vs CNC machining is the material type. While CNC machining suits a wider range of applications, laser cutting is a better fit when processing thin materials, such as metal sheets. 

Laser cutting is suitable for thinner materials (up to 1/4 inch or 6 mm), while CNC machining can handle thicker materials. In addition, laser cutting is a better option when working with delicate or sensitive materials, such as wood, plastics and composites. 

Precision and Accuracy

Since both methods operate under the influence of computer programs, they offer high precision. However, laser cutting is more accurate for small, intricate parts with fine details. The laser beam's focus allows for clean, sharp cuts with minimal tolerance deviations, often exceeding the precision achievable with CNC machining. CNC machining is better suited for complex geometries and 3D shapes

Material Waste and Surface finishing

Both processes are subtractive, so material wastage is almost unavoidable. However, laser cutting typically results in less material waste due to its ability to cut with very narrow kerfs. This efficiency is beneficial for projects where material conservation is critical. This feature also transits into the surface finishing of either process. Remember, unlike machining, laser cutting is a non-contact process, resulting in a smoother and more precise edge. On the other hand, CNC machined parts may require additional finish to correct tool markings. 

Reduced Tool Wear

CNC machining is a contact process requiring friction and attrition between the cutting tool and the workpiece. On the other hand, laser cutting does not use such a tool; it just uses lasers to heat and burn the material. Therefore, there is minimal tool degradation resulting from wear and tear. This feature suggests that laser cutting will require minimal maintenance and tool replacements.

Conclusion

Laser cutting and CNC machining are two unique processes, though they may offer similar results, depending on the manufacturing process. Indeed, laser cutting may be cheaper for simple, precise 2D cuts on thin materials, offering speed and reduced material waste. However, machining too may be more cost-efficient when machining tougher materials or complicated fabrications. Therefore, you still need to examine your precision manufacturing project before deciding which method best suits your budget.