Laser Cutting Laser Use in Tube Processing

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New possibilities in tube processing are emerging at Metallbau Nick thanks to laser technology.

In recent years, sheet metal processing has significantly advanced through the use of laser technology. The focused laser beam melts the metal precisely, enabling accurate cutting and welding. Particularly powerful solid-state lasers have revolutionized the processing of larger material thicknesses, which were previously considered unachievable. This technology has become indispensable in cutting sheets and offers numerous new application possibilities through its flexibility. Even complex geometries can be economically manufactured in small quantities.

For many years, laser technology has been used in tube processing at Metallbau Nick in Lampertheim, Germany. The use of lasers allows for three-dimensional processing of tubes, enabling the creation of a wide range of geometries. The processing begins with inserting a tube into the laser cutting machine. Typically, the standard length of the tubes is 6 meters, a format that most machines can handle easily. Tube lasers are compatible with round, square, and rectangular tubes and can also be used for special profiles like U-profiles with adapted clamping tools. In addition to flexible geometry design, tube lasers offer further advantages: they allow the integration of features that improve the product and optimize and simplify subsequent processing steps.

Pioneer in Tube Laser Technology

At Metallbau Nick, they consider themselves pioneers of tube laser technology. As early as 2001, the first tube laser was acquired and integrated into series production in Lampertheim. The company was able to benefit early on from the advantages, especially with complex tube geometries. A crucial factor for the successful use of tube laser technology is the direct integration of cutting technology into the design. Nevertheless, it often appears that many design departments do not fully exploit the potential of this technology. As an experienced supplier, Nick sees itself as obligated to inform customers about the advantages of tube-laser-oriented design.

An illustrative example of the optimization potential is the production of an L-shaped component from a piece of tube. Traditionally, this would be made from two miter-cut parts and then welded together. With tube laser technology, however, a so-called bend-cut component can be produced. This features positioning aids and is simply bent, significantly reducing the welding effort. Since the component is made from a single piece, stability is maintained, while production time can be reduced by approximately 49 percent and costs by around 31 percent.

Notch cuts—efficient alternative to miter cut technique

Many applications still rely on the traditional miter-cut technique. In this process, tubes are first cut into individual segments and then welded into a frame. This requires precise positioning and additional processing steps. The tube laser offers a more efficient alternative: instead of assembling four individual parts, the frame is manufactured in one piece. Specific cutouts in the tube structure allow the component to be bent 90 degrees at these points. This technique eliminates the need for the laborious positioning of individual parts, as the workpiece maintains a continuous structure. Moreover, often a full circumferential weld can be avoided, as a simple fillet weld suffices.

Another advantage of the tube laser is the ability to create holes or openings in almost any desired shape during the cutting phase. This eliminates additional processing steps on separate machines, saving both time and costs.

Positioning Aids and Connecting Elements

The flexibility of the tube laser allows for the incorporation of individual positioning aids. These range from simple engravings for visual support during assembly to complex bayonet or puzzle connectors that join components with a positive fit. Such connections not only facilitate assembly but also significantly minimize sources of error. Through targeted geometric design, it can be ensured that components only fit together in the correct orientation. This reduces the error rate and, not least, increases process reliability.

Additionally, using tube laser technology, identification features such as part numbers, manufacturing instructions, or positioning indicators can be directly engraved onto the components. This facilitates further processing and ensures seamless documentation in the manufacturing process.

Efficiency Increase Through Modern Tube Laser Technology

The use of tube lasers in manufacturing opens up numerous new possibilities for the economical and precise production of components. However, crucial for maximum efficiency is the early consideration of the technology already in the design phase. Companies benefit from close collaboration with manufacturing partners who have many years of experience in tube laser processing. The combination of technological know-how and optimized manufacturing processes ensures a significant reduction in production times and costs—a decisive competitive advantage for innovative sheet metal processing.

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