Published at signmedia.ca
In the early days of industrial laser equipment, only large, well-established companies could afford it. However, in recent years, decreasing prices have made laser equipment accessible to medium-sized and even small companies.
Laser Welders
Traditional welding techniques such as MIG, TIG, and arc welding have long dominated the industry. While effective, these methods often require highly skilled operators, produce significant heat distortion, and demand extensive post-processing. In contrast, handheld laser welders offer a more efficient solution that addresses these drawbacks and enhances productivity.
The handheld laser welder is suitable for reverse/halo medium to large-sized channel letters, logos made from 0.030", 0.063", and 0.080" aluminum or stainless steel, and structures made from aluminum extrusions (up to ¼" material thickness).
We suggest that sign companies switch to a laser welder, for the following advantages:
- Ease of use — in less than four hours, an operator with no prior experience can learn how to weld 0.030" aluminum.
- High precision and speed, minimal distortion, and a reduced heat-affected zone due to the concentrated laser beam.
- A 2000W fiber laser welder can weld aluminum from 0.030" to 0.27".
- The laser can weld carbon steel, aluminum, stainless steel, copper, brass, and titanium.
- A refrigeration heat pump has been introduced, which lets the laser work 24/7.
- A dual wire feeder is available for bridging gaps between the materials when needed.
- Different thicknesses of material can be welded together.
2000W Laser welder with wire feeder and Argon gas tank on cart:
Reverse/Halo Channel letter:
Aluminum laser welding (Keyence digital microscope):
However, one limitation of the handheld laser welder is that it cannot weld small channel letters. To address this, the QCW Laser was introduced as a solution for small- to medium-sized channel letters.
QCW Laser Welding
In the early days, YAG lasers (using a Neodymium-Aluminum Garnet crystal) were used, but they struggled to weld aluminum effectively.
QCW (Quasi-Continuous Wave) laser welding utilizes a high-peak-power laser to weld materials using short pulses. This method features a smaller heat-affected zone and greater flexibility than continuous-wave (CW) laser welding. A QCW laser operates in high-peak-power pulse modes, providing peak power up to ten times the average power.
Advantages of QCW Laser Welding
- 300W is equivalent to 3000W of other laser types.
- Features a pulsed laser beam, ideal for the narrow strokes of channel letters.
- QCW lasers deliver energy in pulses, allowing the material to cool between pulses — this reduces thermal input and minimizes the heat-affected zone, making it suitable for thin materials.
- The reduced thermal input makes 300W QCW welding ideal for aluminum ranging from 0.020" to 0.040", as well as stainless steel up to 0.040".
- This type of machine can function as a standalone, handheld, or tabletop unit with CCTV capabilities — the ideal solution for small to medium-sized channel letters made from aluminum or stainless steel.
A combination of QCW handheld and tabletop welder (industry first):
Welding a small letter (4") with QCW Laser:
Laser Cutters
Laser cutters are typically categorized into two types:
- CO₂ laser sources for cutting non-metals (newer machines can make steps and grooves)
- Fiber lasers for cutting metals
Laser cutters offer advantages over routers in precision, speed, and the ability to cut complex shapes with non-contact, debris-free cutting. Usually, there is no need for a secondary operation. For the sign company, the laser cutter is an addition to the router, not a replacement.
Many companies cannot afford a fiber laser cutter due to its high cost and space requirements. To overcome the space limitation, some manufacturers introduced the Dual Gantry CO₂ and Fiber Laser Cutter:
- Separate gantries for CO₂ and fiber lasers, allowing for simultaneous processing of different materials.
- CO₂ laser at 500W and fiber laser at 3000W or 6000W.
- Capable of cutting a diverse range of materials, including metals, acrylic, and wood.
- Working area of 5'×10' or 6'×12'.
This machine is ideal for sign companies with high-volume production needs. It can cut a wide range of materials — including acrylic, wood, aluminum, and stainless steel — eliminating the need for two separate machines and saving valuable floor space.
Laser for Small Sign Companies
Small companies aiming to enter the channel letter and logo business can invest in a tabletop CO₂ laser cutter and a 3D printer. This relatively small investment allows the sign company to cut both the front and back with the laser, while the side return can be produced on the 3D printer.
Letters are produced using a 3D printer; the three on the left have faces that are cut with a CO₂ laser cutter.
Safety Concerns
Following basic safety protocols is essential for the safe operation of industrial lasers. Class 4 (IV) lasers are hazardous to the eyes and can cause skin burns.
We recommend the following:
- Safety goggles (OD 7 or 8 for 1064 nm) or a fiber laser welding helmet.
- Wear gloves and protect your arms, neck, and any exposed skin while welding.
- Follow the Laser Safety Standard Operating Procedures (SOP).
- Enclose the machine area with specialized laser partitions (standard welding partitions are not adequate) or solid walls. The laser cutter may be fitted with optional housing.
- For managing fumes and dust generated during welding and cutting, use fume extraction systems. The laser cutter needs to be exhausted to the outside.
Dave Rom, B.Sc. Eng, MBA, is the President and Chief Engineer of Ascent Equipment. He has extensive experience in all aspects of machine manufacturing, with a specialization in CNC bending machines and laser equipment.
For more information, please email dov@ascentge.com or visit ascentequipment.com.
