What Size Laser Is Best for Small Parts Processing?

The lab has carried out tests comparing the marking area and laser power requirements for different materials (such as metal, plastic and ceramics) in order to answer the common question of what size of laser should be used for small parts processing. This helps users choose equipment parameters reasonably according to the material and processing requirements, avoiding wastage of power or insufficient effect.

Why is laser power critical for the processing of small parts?

Many people who are just starting to work with laser processing may think: "These components are so small, any old low-power laser machine will do." Actually, that's not the case.For example, to laser engrave a 5 mm x 5 mm pattern on either stainless steel or acrylic, the energy density required for the former would be two or three times that required for the latter.If the power is too low, the metal surface may not be engraved clearly, and if it is too high, the plastic may be burned through.

Comparison of the actual marking area on different materials.

We tested three common materials--304 stainless steel, ABS plastic, and alumina ceramic--with 20W, 30W, and 50W fiber laser machines.

Material: 304 stainless steel.

- 20W laser: The smallest area that can be clearly marked is 3mm x 3mm, and any smaller will result in blurred edges.

30W laser machine: Can stably process characters 1 mm x 1 mm in size.

50W laser: Though more precise, it has a lower ratio of quality to price than the 30W model.

Non-metallic materials: ABS plastic.

- 20W is sufficient for most applications, and the minimum marking area is 0.8mm x 0.8mm.

But with a 30W machine, you have to be careful about controlling the parameters, because if you're not careful you can scorch a hole in the material.

Special Material: Aluminum Oxide Ceramic.

This type of brittle material requires a "fast in, fast out" approach. The 30W machine performed the best.Tests showed that although the high-power 50W laser had high efficiency, the high heat generated by continuous work affected positioning accuracy and actually slowed overall processing speed.

Three practical tips for choosing a laser.

1. First, clearly identify the main material to be processed. Most metal parts are processed at 30W or more, while pure plastic parts can be processed at 20W.

Don't blindly pursue high power: For every 10-watt increase in power, the cost of the equipment may double, and maintenance costs will also be higher.

3. Reserve 20 % of capacity: For example, if you normally do 2mm engraving, it is best to select a machine that can do 1.5mm.

Finally, it should be noted that the "maximum marking speed" figures given by manufacturers are based on ideal conditions.It is recommended that you personally take samples to try out the equipment, after all, seeing is believing!