How to Perfectly Cut Stainless Steel with A Laser Machine

Working with a material like stainless steel can be challenging, but the rewards are also great. Stainless steel offers a range of advantages, from its strength and durability to its aesthetic appeal to its recyclability. But in order to get the most from a crafting project involving stainless steel, you'll need to be able to shape and cut it. A laser machine is one of the best ways to cut stainless steel, if you've got the right equipment and know-how.

Can You Laser Cut Stainless Steel?

If you've got the right laser machine, you'll be able to cut stainless steel. But just having the correct tool doesn't ensure that you'll be able to execute your project to your specifications. Cutting stainless steel with a laser machine requires preparation and knowledge.

The Difficulty in Cutting Stainless Steel

Because stainless steel is so strong, it requires a powerful laser machine. And that type of power requires incredible precision. You'll need to create a program with your design ahead of time, then properly set and align the cutter before activating it. Any errors in the preparation steps can lead to issues ranging from imprecise cuts to jagged surfaces or other errors.

What Laser Can Cut Stainless Steel?

It's possible to laser cut stainless steel, but you'll need the right type of equipment to do so. Not all laser cutters are capable of handling the job.

CO2 laser cutters are popular among crafters who work with wood, leather, paper and acrylics. But those laser beams aren't powerful enough to handle a heavy-duty material like stainless steel.

Fiber lasers are most effective for cutting stainless steel and other metals. These more powerful laser beams have a wavelength that's particularly well-attuned to metals, making for a smooth and efficient cut.

How to Perfectly Cut Stainless Steel

Executing a perfect cut in stainless steel is a multi-step process that starts before you even think about turning on the laser machine. By following this step-by-step guide, you'll be able to ensure quality work on a repeatable basis.

Step-by-Step Guide

Step 1: Materials Preparation

You'll need to measure and design your cut using a CAD program. After doing so, you'll need to clean the surface of the steel to create a pristine cutting area. Finally, you'll need to firmly clamp the steel in place so that the cut is smooth and accurate.

Step 2: Preparing the Laser Machine

Next, you'll load the CAD file you've created into the machine. Confirm that the assist gas is loaded and in working order. Then, choose a laser power and cutting speed appropriate to the material and thickness. Once all that is in place, test on scrap material to make sure your parameters are producing the result you're looking for.

Step 3: Making the Cut

Engage the laser machine and monitor closely while the cut occurs to confirm that everything is going according to specifications. Be sure to follow all safety procedures while the machine is working. If you observe any issues, pause the machine and make adjustments.

Step 4: Processing After the Cut

Once the cut is complete, check the cutting area for any burred or rough edges, which you can buff out with a deburring tool or sandpaper. Use a mild cleaner on the object and measure its dimensions to confirm that it fits your specifications.

Factors That Affect the Cutting Results

There's a great deal of variability in how you can cut stainless steel, with many factors affecting how your results turn out. Key factors include:

• The thickness of the metal you're cutting
• The power you've set the laser to
• The cutting speed you've chosen
• The type of assist gas you choose
• The gas pressure you've chosen
• The cleanliness of the mirrors in the laser cutter
• The cleanliness of the cutting surface
• Whether the focus is set exactly as it should be

Recommended Stainless Steel Laser Cutting Settings by Thickness

The two main factors that will determine the best laser machine settings are the material you're cutting and the thickness of the object you're working on. In this case, we're cutting stainless steel, so the biggest question is how thick the material in question is.

A variety of resources provide charts that recommend cutting speeds and power for different thicknesses of stainless steel. These charts usually measure thickness by millimeters, and the general rule is that thicker materials will require slower cutting times and higher cutting power.

Consult one of these charts to determine your initial settings, and always be sure to test those settings with scrap steel before moving on to your real cut. While these guidelines are usually accurate, other factors may require you to make adjustments to get the perfect cut.

Causes and Solutions for Common Stainless Steel Cutting Problems

If you're experiencing issues while cutting stainless steel with a laser cutter, don't get discouraged. There are a handful of common issues that crafters typically encounter when cutting stainless steel, and most of them can be solved fairly easily.

Burring, where the cut edge is sharp, rough or elevated, is a common issue when cutting stainless steel. Burring usually happens when molten metal isn't ejected from the cutting area. The three most common reasons for burring are the focus being incorrectly set (usually too high), too-slow cutting speed, and low assist gas pressure. Adjust these settings to take care of burring issues.

Poor cut edge quality can overlap with burring, but can also include factors like an incomplete cut and other issues. Generally, poor edge cut quality comes down to improperly chosen settings, and can be fixed by adjusting those. Another common reason for poor edge cut quality is contaminants on the material, so taking extra care to clean the steel before cutting may solve your problems.

Another common issue is edge discoloration. Edge discoloration is usually caused by the oxidation process, when the metal is exposed to oxygen and high heat. The culprit is often either too-slow cutting speed or too-high cutting power, but the assist gas can also play a role. Nitrogen is a particularly good assist gas if you're worried about edge discoloration. Also, keep in mind that sometimes edge discoloration can be solved by vigorous cleaning after you've made the cut.

Tips for Perfect Cutting

When cutting stainless steel, there are a handful of tips and tricks that will increase your chance of success, especially when you're relatively new to the process. Following these guidelines will lead to perfect cutting and successful projects.

First of all, cleanliness is key. That goes for the material you'll be cutting, but also your laser machine and the surrounding environment. The fewer contaminants and less impurity in the vicinity of your cut, the better.

Never be afraid to do a little more testing before making the real cut. As long as you've got scrap steel available, be sure to confirm that all your settings and specifications are going to produce the result you're looking for before cutting your actual material.

When it comes to assist gas, nitrogen is almost always going to be the right choice for stainless steel. Stainless steel's bright surface makes it particularly vulnerable to oxidization and discoloration, and nitrogen fights that process. For extremely thick stainless steel cutting jobs, argon may be better suited, but it's also considerably more expensive. Usually, oxygen will be a poor choice because of its oxidizing potential.

How xTool Machines Help to Excel at Stainless Steel Cutting

xTool offers a wide range of products perfect for all manner of cutting and engraving projects, spanning from softer materials like wood and textiles to heavy-duty materials like steel and other metals. Two of their offerings are particularly good for cutting stainless steel.

The first, the xTool F2 Ultra, is a versatile laser cutter with a dual-laser setup able to handle both metals and non-metal materials. That makes the F2 Ultra an ideal choice if you're planning on cutting not just stainless steel and other metals but a variety of materials. The F2 Ultra also allows for color engraving on metals and a user-friendly enclosed design with extra safety features.

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The second, the xTool MetalFab, is a heavy-duty machine capable of cutting, welding, engraving and cleaning all manner of metal materials. The MetalFab shines when you're looking for a one-stop solution for all your metalworking-related needs, delivering industrial power with a process that's accessible to a novice. The MetalFab is also highly cost-effective if you're planning to use multiple of its functions, sparing you the need to purchase more than one piece of heavy equipment.

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Both these machines are fully capable of handling stainless steel cutting projects. Deciding which one might be right for you comes down to what kind of projects you anticipate working on and what those requirements might be.