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Laser Machining Processes - 3D Laser Milling, Laser Micro-Machining
3D laser milling is a new laser machining process which uses a laser beam to machine 3 dimensional shapes into a wide variety of materials. 3D laser machining works much like stereolithography, only in reverse. Instead of building up an object one layer at a time, the material is removed 1 layer at a time. Material removal is by means of ablation.
When programming a 3D laser machining job, the form is sliced up into layers typically 2 microns thick. The machine is programmed to remove material only from the area that makes up the layer in question. Material is removed by the machine 1 layer at a time in a cross hatch pattern until the 3D shape is machined.
Laser frequency, speed and current are controlled as user parameters to laser machine various types of materials, control cutting speed and surface finish. 3D laser milling is suitable for a wide variety of materials including hard materials such as tungsten, carbide and ceramic. An excellent, ‘EDM’ type of matt finish is imparted to the surface. Cavities having straight walls and complex curves are possible. However, undercuts are not possible and shallow curves tend to show the small steps between layers.
3D laser machining is a ‘set and forget’ process where once programmed, there is no cutters to break nor electrodes to wear allowing trouble free, unsupervised machining and freeing up operators for other tasks.
3D laser milling is a process well suited to machining of very finely detailed cavities or micro fluidic channels. As a machining process for micro injection molding cavities 3D laser machining can save time if the mould cavities have a great deal of detail and are fairly shallow. Finely detailed coining dies are a good example of the sort of mold cavity suited to laser machining.
The main limitations of this process are the slow material removal rates and the visibility of the steps between each layer. Especially on shallow curves, the steps are quite visible, but can be disguised with the new surface hatching procedures available from the programming software.
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