sponsoredThe Right Solution for Every Need Trumpf Expands Its Portfolio for 2D Laser Cutting

With the new generation of the Trulaser 5000 series, Trumpf aims to address current challenges in sheet metal processing—while demonstrating that its product portfolio, ranging from entry-level to fully automated machines, offers the right solution for every need.

The demands on sheet metal fabrication companies are growing year after year: Customers expect shorter lead times, tighter tolerances, and cost-effectiveness even for single-unit production, while at the same time there is a shortage of skilled workers to operate the equipment competently. Competition is intensifying, processes are becoming more complex—and the question of how existing machine capacity can truly be translated into productivity is becoming increasingly urgent.

The paradox is this: In many cases, the technological capabilities have long been available. Internal analyses by Trumpf show that customers often make only partial use of the information and technological features provided for their machines. Even experienced users sometimes don’t discover reports like those in the company’s “Smart View” analysis software until much later. One reason for this is that operators are rarely trained by the manufacturer but are instead primarily trained “on the job.” As a result, new features often go undiscovered. This creates a gap between what a machine is technically capable of and what is actually utilized in day-to-day operations. In addition, customers often lose more productive time than necessary due to unplanned downtime.

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With the new generation of the Trulaser 5000 Series, Trumpf aims to close this gap. The high-productivity 2D laser cutting machine combines powerful hardware, intelligent assistance functions, software, and services with the company’s many years of process expertise in laser cutting. The goal is to create transparency, actively support the operator, and continuously improve the machine’s performance.

See More, React Faster

The starting point for this new development was a sober assessment of the current situation in the field: Nearly half of all machine downtime is caused by collisions—yet features designed to reduce such incidents are often not used, are unknown, or are simply not desired. In addition, production operators no longer work on just one machine and need assistance to keep track of multiple machines at the same time. Furthermore, visibility has not always been sufficient, especially with larger machines.

The new Trulaser 5000 addresses all of these issues. Real-time notifications immediately indicate where assistance is needed. In a multi-machine view, operators and production managers can see at a glance the status, remaining run times, and camera feeds for all connected machines in the shop floor. This allows an operator to monitor multiple machines simultaneously while still being able to react quickly if action is needed anywhere.

To this end, the control panel will now feature two monitors stacked one above the other, displaying significantly more data than before. On the second screen, the operator can call up an overview showing which programs have experienced an unusually high number of collisions and the resulting downtime—analyzed by program or by technology table, with trend data over days, weeks, or months. Programmers in the office can also access this information and fine-tune cutting programs as needed. Manual tracking of downtime is no longer necessary; the machine provides the figures automatically.

The new vision equipment provides a view inside the machine: Five camera angles are installed as standard on the new series and cover the entire interior of the machine—including a front view, side views of the machining area, a camera mounted on the cutting head that moves with it, and a view of the pallet changer. The images can be viewed both directly at the machine and remotely via the customer’s network using the Smart View software—for example, on a tablet.

Continue Running Automatically Instead of Intervening Manually

In addition to greater transparency, Trumpf is focusing on greater autonomy in the ongoing process. The Active Speed Control feature monitors key process parameters during laser cutting, regulates the feed rate, and also checks the condition of the cutting nozzle—eliminating the need for a manual nozzle inspection. If a cutting error does occur, Smart Rerun kicks in: This feature ensures that, in more than 90 percent of all cases, the machine automatically resumes or continues cutting on its own. Overall, this reduces downtime per machine by an average of 70 hours per year. This figure makes a noticeable difference, especially in automated and minimally staffed operations, because fewer operator interventions are required and production continues more consistently.

This is complemented by condition monitoring: Trumpf continuously monitors the condition of key machine components using integrated diagnostics and the expertise of its own service specialists. Impending failures are detected early, allowing maintenance measures to be planned proactively rather than reactively. Unforeseen downtime is thus transformed into plannable service events, thereby preventing approximately one-third of quality losses and downtime. By way of comparison: Some Trumpf customers are already achieving 98 percent machine availability—a target the company aims to extend to a broader customer base in the future.

Another key component for operational safety is the five-chamber exhaust system, which efficiently removes fumes and airborne particles from the cutting process, thereby ensuring a clean work environment.

With the Trulaser 5000, Trumpf is introducing a solution to the market that is constantly evolving. Insights gained from the machines that Trumpf has installed at customer sites around the world—and which are connected to Trumpf’s IT system—are continuously incorporated into the further development of the series. This is based on a powerful hardware infrastructure consisting of an industrial PC and a modular camera system, which is kept up to date through regular security and feature updates.

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From the Basics to Fully Automatic Machines

Of course, the Trulaser 5000, as the new flagship model, marks a milestone. At the same time, Trumpf emphasizes that there is no one-size-fits-all solution—rather, there is the right machine for every requirement. The product portfolio is structured in a clear, step-by-step progression, ranging from a user’s first laser system to a fully automated production line.

The Trulaser 1000 Series serves as the entry point, offering various sizes ranging from approximately 3 by 1.5 meters (9.8 by 4.9 feet) up to 6 by 2.5 meters (19.7 by 8.2 feet). It is aimed at companies that do not yet have in-house production capabilities for sheet metal parts or that need suitable machines for small production runs, and, according to Trumpf, offers the perfect entry point into laser cutting for establishing long-term production. The entry-level segment is complemented by the Trubend 1000 Series—a compact press brake with a 4-axis backgauge that can be operated intuitively via Teczone Bend and fits even in smaller workshops.

A step above that, the Trulaser 3000 Series positions itself as an all-around machine offering maximum flexibility, with sheet sizes up to 8 by 2.5 meters (26.2 by 8.2 feet) (3080 fiber), laser powers up to 24 kW, and speeds up to 170 m/min (558 ft/min). For those who also require bevel cuts, the Trulaser 3000 Series Bevel Cut Edition represents a logical evolution: It cuts bevels up to 50 degrees directly during the machining process, thereby eliminating the need for subsequent processes. The result is fewer processing steps and greater flexibility.

The third tier is the Trulaser 5000 Series—already described in detail—which serves as the flagship model for demanding manufacturers with high throughput. It can also be seamlessly integrated with automated storage and sorting solutions such as Sortmaster Station, Sortmaster Vision, or Trustore, thereby evolving into a fully integrated manufacturing system.

The portfolio is rounded out by the Trulaser Center 7030—the compact, fully automated laser machine. It covers the entire machining process through to part separation, thereby promising minimal machining costs with maximum efficiency—all from a single source, from the drawing to the finished, sorted part.

Trumpf clearly articulates the overarching rationale behind this portfolio approach: It’s not just a machine that’s delivered—the scope of delivery includes the machine, laser, automation, software, and digital services—all from a single source and backed by an international service network. Only the customer’s specific application determines which laser machine is the right one, regardless of the mix of materials being processed.

A Journey That Continues

For Trumpf, Euroblech is explicitly a milestone, not a destination. The new Trulaser 5000 Series marks the next step toward a fully data-driven, high-performance machine that not only provides customers with information but also offers them concrete recommendations for operating their equipment. For users, this means that when you work with Trumpf, you don’t just get a laser cutting machine. You get a tool tailored to your specific operations—and a platform that grows with your needs.

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