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Aerospace & Defense Metal Cutting & Forming 21 Nov 2025

Laser Cutting

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updates@lform.com

“The broad range of manufacturing services provided by Fathom all under one roof combined with their deep technical expertise is unique. By leveraging the company’s on-demand platform, we sourced from one proven supplier that made the overall process seamless. Their flexible solutions paved the way so that we could iterate more efficiently and speed our time to market, a big advantage for us. Fathom executes at a very high level, and we intend to partner with the company on other projects going forward.”
Manufacturing Engineer
VSi Parylene

How

01 Types of Lasers Used

Laser cutting utilizes a CNC-controlled, high-powered laser beam to cut, engrave or etch material. Because the kerf width is barely larger than the laser beam, it can be used to cut very fine geometries and intricate shapes. There are two main types of laser cutters used to cut sheet metal: CO2 and fiber lasers. In addition to cutting, a laser cutter can etch sheet metal to add features such as part numbers or serial numbers.

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02 The Cutting Process

Laser cutters follow the CAD design to create cuts, holes and engrave the sheet metal. Our fiber laser cutters have a kerf width of .008 inches. That makes them ideal for cutting complex details. Our lasers can cut .010-.50″ thick materials, +/- .005” with the possibility of tighter tolerances based on project specs. We can cut a wide range of materials, including aluminum, carbon steel, stainless steel and copper.

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03 Post Processing

Industrial laser cutting produces high-quality edge finishes that require little or no post-processing. Some cleanup of burn marks may be required. The laser may also cause narrow heat-affected zones along the cuts, which could affect the properties of the metal, including brittleness, oxidation and corrosion. Post processing for laser-cut sheet metal may include deburring, sanding, polishing, welding, painting, and anodizing.

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Advantages & Disadvantages of Laser Cutting

Advantages

  • Affordability

    High speed and high quality make industrial laser cutting very cost-competitive and a real value for our customers. It’s an ideal process for prototype to low-volume production quantities of laser cut parts.

  • Automation

    Laser cutters at our Denver facility are equipped with automatic loading and unloading systems, enabling us to process large orders on a lights-out basis. That helps us keep our costs competitive and helps us deliver your finished parts faster.

  • Precision Details

    Laser cutting can produce small, precise holes and fine details in sheet metal.

  • Tight Tolerances

    CNC controls maintain critical tolerances while accommodating fine features and larger blank sizes.

  • Quick Turn-Around

    Laser cutting jobs can be set up and running quickly – perfect for fast turnarounds on small batches of parts. Because laser cutting doesn’t apply any physical forces to the sheet metal, it doesn’t need to be held in place with jigs or work-holding fixtures. That speeds up the setup and production times.

  • Little or No Finishing Required

    Industrial laser cutting produces high-quality edge finishes that require little or no post-processing. Some cleanup of burn marks may be required.

  • Maximize Material Use

    Multiple parts can be cut from the same sheet. That helps to minimize waste.

Disadvantages

  • Heat-Affected Zones

    Because laser cutting generates heat, it can alter the chemical and structural characteristics of the metal near the cutting edge – called “heat-affected zones” (HAZ). Effects may include oxidation, brittleness and corrosion. However, laser cutting generates smaller heat-affected zones than other thermal cutting techniques.

  • Material Limitations

    Laser cutting can’t cut through thicker sheet metal. Water jet cutting works better for thick materials.

Applications That Can Benefit From Laser Cutting

Automotive & Aerospace
These industries need precise, high-tolerance parts for a variety of applications. Laser cutting can cut complex shapes in tough metals that are needed for these demanding industries.

Medical Equipment
Laser cutting is used to cut large panels for X-ray and MRI machines. It’s also used to build enclosures for a variety of monitoring equipment. The exceptional efficiency of laser cutting makes it a popular choice for cost-conscious medical device manufacturers.

Electronics
Laser cutting of sheet metal is used to create enclosures and precision components for a wide variety of electronic devices. Its quick turnaround makes it especially attractive as a tool for rapid prototyping of new devices. 

Off-Highway Equipment
Laser cutting is used to cut durable body panels and other components for construction, mining and agricultural equipment.

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