Combining two production technologies – punch and laser – in a single machine provides more capability for the investment. With punch-laser combination equipment now available at more affordable price points, and as more fabricators bring work in-house to lessen the impact of tariffs and reduce reliance on suppliers, this hybrid system deserves a closer look.
When is a punch-laser machine the right combination? While there could be dozens of reasons, here are six that could apply to almost any fabrication shop.
1. High-mix, low-volume or low-mix, high-volume
The punch-laser machine delivers high efficiency across different manufacturing environments. It can output at high volumes and easily transition to low-volume or prototyping applications, maintaining performance in both. Because the combination machine is adaptable to varying production needs, it fits both job shops and OEMs. With integrated punching and laser cutting capabilities, the machine eliminates the tradeoff between flexibility and economies of scale.
This flexibility is especially valuable for the job shop. If a part only requires a few features, they can be quickly and easily laser cut without the need for a tooling investment. Tooling is only required for parts with a high concentration of holes or for forming operations that are best suited to the punch press. The laser can cut features that are difficult or impossible to punch, such as very small holes, intricate details and sharp angles. For example, when producing a box tray that requires a bend relief, the laser can efficiently cut relief lines, resulting in a cleaner and better-formed part. It can also handle features that are too large to be punched in a single hit.
Even with the tooling on hand, the punch-laser machine provides the flexibility to bypass the tool setup and simply laser cut the job. This reduces setup time 100 percent and allows the work to get done quickly, which is ideal for very small part runs and for parts for which the customer didn’t specify a process preference and can be produced either on the punch press or the laser.
The laser also enables dynamic nesting. Parts can be rotated on the fly to get more parts per nest and per sheet. This increases output and reduces the framework, webbing and punch cutouts.
It’s common for a punch-laser machine user to punch the internal part features and then laser cut the perimeter. This leaves a smooth, clean exterior edge that needs no deburring, something not achievable with nibbling on the punch press. This is an ideal way to use the strengths of both technologies to get the best results.
The technologies of a punch-laser machine can also be used independently for applications that require only punching or laser cutting. While each process has its limitations when used on its own, this versatility adds even more value.
2. Manufacturing is more complex
As product designs evolve, manufacturing requirements become more complex. Near-zero tolerances are needed for critical parts for aerospace; advanced materials and special alloys are more commonly used; and demand for more customized products requires more flexibility in manufacturing.
By bringing together the strengths of both technologies, a punch-laser machine makes it easier to produce complex parts with high precision and consistency. The laser cuts intricate inner and outer contours with high edge quality. The punch can form profiles, tap, add louvers and even countersink. And because this happens on a single machine in a single setup, there’s less chance for errors and more repeatable quality.
Even for parts that don’t require forming, combining punching and laser cutting on a single platform offers clear quality advantages. This is especially true with today’s advanced punch-laser machine, as both technologies have evolved:
- The fiber laser delivers a high edge quality and stands out for its speed and efficiency, making it a highly productive technology. Its low operating cost helps reduce the overall expense of running a punch-laser machine.
- Modern punch presses offer better machine dynamics with movement in both the X and Y axes for faster punching speeds.
- Machine control and software have also improved. Built-in macros and intuitive CAM software make programming and job setup nearly automatic.
3. Streamlining workflows is an objective
A streamlined workflow is a key building block of a smart factory. When dealing with bottlenecks, redundant steps in the manufacturing process, quality issues or all of the above, integrating punching and laser cutting into a single machine can be a smart solution for a more streamlined workflow. Traditionally, a fabricator laser cuts blanks and then moves them to the punch press one at a time, maybe to add a louver or countersink. With the punch-laser machine, this is streamlined in one process. Completing multiple operations on one machine reduces errors, inconsistencies, production time and the use of resources.
For example, a shop was punching or laser cutting a large part with baffles, then moving it to a secondary operation to add countersinking. A single part took more than 7 min. to laser cut, plus added time for countersinking. The punch-laser machine processed two of these parts in 6 min. with no secondary operation needed.
4. Enhancing value for a competitive gain
The flexibility of the punch-laser machine helps add value to parts and products and for less cost. The laser can cut features that would be too small to punch and cut detailed shapes or sharp corners difficult to punch without investing in specialized tooling. The punch can add value by also forming, tapping and deburring.
5. Automation is on the radar
Today’s punch-laser machine incorporates automation in a way that lasers and stand-alone machines can’t. It offers dedicated part handling and removal in the form of drop-door or work-chute systems for both punch and laser, skeleton removal, and part picking and sorting in real time. Completed parts can leave the machine from the drop door onto a conveyor or into a bin sort system or can be evacuated onto a pallet underneath the table. Advanced systems can pick a part off of the metal sheet and place it on a pallet, ideal for parts that are too large for the drop door. Parts can be sorted and palleted during lights-out operation leaving just the worksheet skeletons for disposal.
Having a single multi-purpose automated machine means less skilled labor is required to operate the machine and handle parts.
6. Floor space is limited; making the most of current space
A single machine occupies less floor space than two separate systems. While this may seem minor, it’s a real advantage for fabricators with space-constrained facilities. Even for shops with ample floor room, it makes sense to make the best use of production space. With a growing focus on sustainability, reducing resource consumption and minimizing waste, a combination machine aligns with these goals. This provides operational efficiency as well as a potential competitive edge.
Start to finish
Fabricators that are unfamiliar with punch-laser machines or haven’t evaluated one in a while may be surprised by how versatile and cost-effective they have become. Combination machines can process a wide range of part geometries and materials and come equipped with advanced automation features to make the job easier and more economical.
A punch-laser machine can laser cut metals and non-metals up to 3/8 in. thick and punch materials up to 0.25 in. with hit rates of up to 440 hits per min. on 1-in. centers. With high-quality laser cutting and integrated forming, it provides a “start to finish” solution. It’s this flexibility that makes the punch-laser machine a great fit for all kinds of production needs in modern metal fabrication.
