When deciding between laser cutting and metal stamping processes, there are a number of process-specific advantages to consider. Laser cutting requires no upfront investment in tooling, reducing the turnaround time of projects significantly. On the other hand, metal stamping can better support high-volume, repetitive part production.
Both techniques can deliver a range of metal components and can enhance production with specific applications. We will explore the differences between metal stamping and laser cutting, highlighting the benefits and limitations of each method.
Key Considerations
The right manufacturing method will look different depending on your application’s needs. Some projects may benefit from high-speed manufacturing processes, while others may require more design complexity or rapid turnaround times.
We’ve outlined some key considerations to help you choose the method that best fits your project requirements:
Time
Laser cutting relies on a digital setup process that allows for rapid start times, making it ideal for small-volume production runs and prototyping. Components can be designed, produced, and finished in a few days or weeks. With metal stamping, pre-production processes such as engineering and manufacturing the die can take weeks to complete.
However, metal stamping machines can maintain a steady rate of production once tooling is complete, continuously running as metal is fed into them. Large-scale facilities can produce up to one million components using this process. Laser cutting delivers pieces at a slower pace but allows the manufacturer to change design geometries without costly and time-intensive retooling.
Cost Effectiveness
Metal stamping can be cost-effective for high-production volumes, with a higher upfront cost that decreases as the number of required units increases. A manufacturing facility can use a single die to stamp over one hundred thousand components before needing to replace the die. Manufacturers can also combine multiple operations in a single stamping process, including fastening, extruding, and tapping, reducing overall part costs.
Laser cutting’s cost advantage comes from eliminating tooling expenses, allowing manufacturers to produce small batches or prototypes at a lower upfront cost. Laser cutting is also receptive to automation, which can greatly reduce labor costs compared to manual machinery used in metal stamping.
Efficiency
Metal stamping allows manufacturers to produce high volumes of components in a short period once the die has been created, which can increase overall efficiency in larger production runs. Laser cutting delivers components with smooth edges, which eliminates the need for secondary finishing and smoothing operations. Laser cutting also produces components individually, which reduces waste from single-component errors.
Reliability
When mishandled, metal cuts and bends can lower the structural integrity of your components. For instance, unintended motion during cutting (or even a bend that’s too deep for the metal’s internal radii limitation) can make the metal component brittle and easier to break. Metal stamping dies should be checked and replaced during high production volumes to maintain reliability and consistency.
Laser cutting is computer-controlled, repeatedly producing parts with exact dimensions and zero practical variance. Laser cutting reduces physical contact with the material, which minimizes the risk of defects during the cutting process. Errors during the laser cutting process only affect a single component, reducing the need to replace or remake an entire batch during production.
Investment
Metal stamping and press brake machines require routine maintenance to keep them working in top condition. Tools and dies can wear out rapidly from constant use, particularly with hard metal alloys like 430 stainless steel. Maintaining stamping equipment can be costly, with new dies ranging from $5,000 to $500,000. However, manufacturers can use this equipment to meet extremely tight tolerances (as low as 0.0005-inch) for consistent performance and quality across products.
Laser cutting requires no tooling and makes minimal contact with the workpiece. This means the laser cutter experiences far less wear and tear and costs less to maintain compared to metal stamping equipment. The machine’s laser diode is a replaceable component that offers stellar performance over many production runs.
Flexibility
Laser cutting offers greater flexibility, allowing manufacturers to change design and geometry elements during production without retooling. Laser cutting machines can also produce components of various thicknesses and material compositions. Metal stamping equipment and press brakes have a limited amount of force they can apply to workpieces with a single die, which limits the materials and thicknesses metal stamping machines can handle. Additionally, a new die must be created to make any changes in part geometry.
Material Thickness
While laser cutting machines can cut metals in a range of thicknesses, high-tonnage presses may be more suitable for forming and cutting thicker metal pieces. Metal stamping can deliver extremely tight tolerances (as low as 0.0005-inch) compared to laser cutting, which offers tolerances of 0.001 to 0.002-inch.
Versatility
Press brake and metal stamping machinery offer more than just cutting holes in material. Metal stamping machines also offer coining, swaging, and flattening functions to meet specific project requirements. Press brake machines can bend and shape steel wire forms and sheet metal to specific angles and achieve complex shapes for various applications.
Laser cutting is not suitable for use with certain alloys, as extreme heat can alter their material properties. Metal alloys that resist high temperatures can also be challenging to cut with lasers because of their high melting points. Press brake and metal stamping machines should be used with these alloys.
Speak to the Metal Fabrication Experts at American Industrial
While a myriad of factors go into selecting the right manufacturing method for your project, there are some clear advantages to each process. Laser cutting enables precise cuts and greater design flexibility, which can prove useful with smaller batches and prototypes. Press brake and metal stamping techniques are used to complete larger production runs, offering lower costs per piece and high-speed manufacturing after tooling.
American Industrial Company has been delivering custom metal fabrication solutions since 1981. We use metal stamping, press braking, and laser cutting processes to help customers achieve a range of project goals.
Request a quote or reach out today to speak with an expert about your project requirements.