The Complete Guide to Laser Cutting: Technology, Applications, and Services in Australia
Laser cutting has revolutionized modern manufacturing, offering unprecedented precision and versatility across industries. From intricate steel fabrication to creative MDF projects, laser cutting technology enables manufacturers and hobbyists to achieve clean, accurate cuts that would be impossible with traditional methods. This comprehensive guide explores everything you need to know about laser cutting, from the underlying technology to finding the best laser cutting services in Australia. Whether you're researching laser cutting Brisbane or laser cutting Sydney options, or considering investing in your own equipment, this article covers the essential knowledge you need to make informed decisions about laser cutting applications for your projects.
What is Laser Cutting and How Does It Work?
Laser cutting is a thermal separation process that uses a focused laser beam to cut through various materials with exceptional precision. The process works by directing a high-powered laser beam through optics and computer numerical control (CNC) systems to follow a predetermined cutting path. When the laser beam contacts the material surface, it rapidly heats, melts, burns, or vaporizes the material, creating a clean cut edge.
The fundamental principle behind laser cutting technology involves three key components: the laser generation system, beam delivery system, and cutting head assembly. The laser generates coherent light that maintains its intensity over long distances, while sophisticated mirror systems and fiber optics deliver this energy precisely to the cutting location. Modern laser cutting machines achieve tolerances as tight as ±0.1mm, making them ideal for both industrial manufacturing and precision prototyping applications.
Unlike traditional mechanical cutting methods, laser cutting is a non-contact process that eliminates tool wear and reduces material distortion. This contactless approach enables cutting of delicate materials without mechanical stress, while the narrow kerf width (typically 0.1-0.5mm) minimizes material waste. The heat-affected zone remains minimal, preserving material properties adjacent to the cut edge.
Key Advantages of Laser Cutting Technology
The versatility of laser cutting applications stems from several inherent advantages over conventional cutting methods. First, the precision achievable with laser systems far exceeds most mechanical alternatives, enabling complex geometries and tight tolerances essential for modern manufacturing. The automation capabilities allow for consistent quality across large production runs while maintaining the flexibility to switch between different designs rapidly.
Speed represents another significant advantage, particularly for thin materials where laser cutting can achieve cutting speeds of several meters per minute. The clean cut edges often eliminate secondary finishing operations, reducing overall production time and costs. Additionally, the ability to cut a wide range of materials—from metals to textiles—with the same equipment provides exceptional manufacturing flexibility.
Types of Laser Cutting Technologies
CO2 Laser Cutting Systems
CO2 lasers represent the most established laser cutting technology, utilizing a gas mixture to generate infrared laser light at 10.6 micrometers wavelength. These systems excel at cutting organic materials like wood, acrylic, leather, and textiles, making them popular for laser cutting MDF projects and creative applications. CO2 lasers also effectively cut thin metals, though their performance on reflective materials like aluminum requires special considerations.
The versatility of CO2 systems makes them ideal for businesses requiring diverse material processing capabilities. Modern CO2 laser systems can seamlessly transition from cutting thick MDF panels for furniture manufacturing to processing delicate fabrics for textile applications. The relatively lower initial investment compared to fiber lasers makes CO2 technology accessible for small to medium-sized operations exploring laser cutting business opportunities.
Fiber Laser Cutting Systems
Fiber laser technology has gained significant traction in industrial applications, particularly for laser cutting steel and other metals. Operating at approximately 1 micrometer wavelength, fiber lasers achieve superior absorption rates in metals, resulting in faster cutting speeds and lower operating costs. The solid-state design eliminates consumable gas requirements and reduces maintenance compared to CO2 systems.
For laser cutting stainless steel applications, fiber lasers deliver exceptional edge quality with minimal heat-affected zones. The technology excels at processing reflective metals that traditionally challenged CO2 systems, including aluminum and copper alloys. The efficiency of fiber lasers—often exceeding 30% electrical-to-optical conversion—significantly reduces energy consumption, making them environmentally sustainable choices for high-volume production environments.
Diode and Crystal Laser Systems
Diode lasers represent the entry-level segment of laser cutting technology, popular for hobbyist applications and small-scale production. While limited in power output compared to CO2 and fiber systems, diode lasers offer affordability and ease of use that appeals to makers and small businesses. These systems work well for thin materials and engraving applications, though cutting capabilities remain limited to materials under 5mm thickness typically.
Crystal lasers, including Nd:YAG and Nd:YVO4 systems, occupy a specialized niche in laser cutting applications. Their ability to deliver high peak power in pulsed mode makes them suitable for cutting very thick materials or specialized applications requiring precise heat control. However, the complexity and cost of crystal laser systems limit their adoption primarily to specific industrial applications where their unique capabilities justify the investment.
Materials Suitable for Laser Cutting
Metal Laser Cutting Applications
Metal processing represents the largest segment of industrial laser cutting applications, with laser cutting steel leading in volume and diversity. Mild steel, carbon steel, and alloy steels respond excellently to laser cutting, achieving clean edges and precise dimensions across thicknesses ranging from 0.5mm to over 30mm depending on laser power. The automotive, construction, and machinery manufacturing industries rely heavily on steel laser cutting for components ranging from brackets to complex structural elements.
Laser cutting stainless steel requires specialized techniques to manage the material's reflective properties and thermal characteristics. Stainless steel grades 304 and 316 are commonly processed, with applications spanning food service equipment, medical devices, and architectural elements. The corrosion resistance and aesthetic appeal of laser-cut stainless steel make it particularly valuable for visible components where both function and appearance matter.
Aluminum laser cutting presents unique challenges due to the material's high reflectivity and thermal conductivity. Modern fiber laser systems have largely overcome these obstacles, enabling efficient processing of aluminum alloys for aerospace, automotive, and consumer electronics applications. The lightweight properties combined with precise laser cutting capabilities make aluminum an increasingly popular choice for weight-sensitive applications.
Non-Metal Material Processing
Laser cutting MDF (Medium Density Fiberboard) represents a significant application area, particularly for furniture manufacturing, architectural models, and decorative elements. The uniform density of MDF enables consistent cutting quality, while the material's stability prevents warping during the cutting process. Creative industries leverage MDF laser cutting for everything from intricate decorative screens to precision furniture joints that would be impossible to achieve with traditional woodworking tools.
Acrylic and plastic laser cutting serves diverse industries from signage to medical device manufacturing. The clean, polished edges achievable with laser cutting eliminate secondary finishing operations common with mechanical cutting methods. Thickness capabilities range from thin films to blocks over 25mm thick, enabling applications from delicate microfluidic devices to robust industrial components.
Textile and leather laser cutting has transformed fashion and automotive industries by enabling intricate patterns and precise shapes impossible with traditional cutting methods. The sealed edges prevent fraying in fabrics while maintaining the flexibility essential for clothing and upholstery applications. Automotive interior components, fashion accessories, and technical textiles benefit from the precision and consistency of laser cutting technology.
Choosing the Right Laser Cutting Service
Evaluating Service Capabilities
When searching for laser cutting services near me, several critical factors determine service quality and suitability for your specific requirements. Material compatibility represents the primary consideration—ensure the service provider has experience with your specific materials and thicknesses. Equipment capabilities, including maximum cutting area, thickness limits, and precision specifications, directly impact project feasibility and cost-effectiveness.
Quality certifications and industry standards compliance indicate professional service providers committed to consistent results. Look for certifications such as ISO 9001 for quality management systems and industry-specific standards relevant to your application. Quality is the cornerstone of any successful laser cutting company, and established providers invest in continuous improvement processes that benefit their customers through reliable service delivery.
Turnaround time and production capacity significantly impact project schedules, particularly for time-sensitive applications. Established service providers typically maintain multiple laser systems and backup equipment to ensure consistent delivery schedules. Rush services and emergency capabilities can be crucial for prototype development and urgent repairs, though these services typically command premium pricing.
Geographic Considerations in Australia
Laser cutting Sydney services benefit from the concentration of manufacturing and engineering businesses in Australia's largest metropolitan area. The competitive market environment drives innovation and competitive pricing, while proximity to major ports facilitates material sourcing and export capabilities. Sydney-based services often specialize in high-precision applications serving aerospace, medical device, and electronics industries.
Laser cutting Brisbane providers serve Queensland's growing manufacturing sector, including mining equipment, agricultural machinery, and marine applications. The subtropical climate considerations may influence material handling and storage practices, while the proximity to mining and agricultural industries often drives specialization in heavy-duty cutting applications and wear-resistant materials.
Regional service providers throughout Australia offer advantages including lower overhead costs, personalized service, and specialized knowledge of local industry requirements. While equipment capabilities may be more limited compared to metropolitan providers, regional services often excel in customer relationships and flexible service offerings that benefit small to medium-sized businesses.
Design Guidelines for Laser Cutting Projects
Optimizing Designs for Laser Cutting
Effective laser cutting design requires understanding the capabilities and limitations of the cutting process. Minimum feature sizes depend on material thickness and laser kerf width, typically ranging from 0.1mm for thin materials to several millimeters for thick sections. Sharp internal corners require special consideration, as laser cutting naturally produces rounded corners with radius approximately equal to half the material thickness.
Design for manufacturing principles become particularly important in laser cutting applications where small design modifications can significantly impact cutting time and cost. Optimizing part nesting—the arrangement of multiple parts on a single sheet—maximizes material utilization and reduces per-part costs. Experienced designers incorporate cutting sequence considerations to minimize heat buildup and maintain dimensional accuracy across complex parts.
File format requirements and design software compatibility ensure smooth project execution. Most laser cutting services accept DXF, DWG, and AI vector formats, though specific requirements may vary. Proper layer organization, line weights, and color coding help communicate cutting instructions clearly, reducing the likelihood of errors and revisions that can delay project completion.
Material-Specific Design Considerations
When designing for laser cutting steel applications, thermal expansion and heat-affected zone considerations become critical for maintaining dimensional accuracy. Thick steel sections may require special cutting techniques such as oxygen-assisted cutting or multiple passes to achieve complete penetration. The design should account for potential heat distortion in thin sections and include appropriate fixtures or cutting sequences to maintain flatness.
Laser cutting MDF projects require attention to grain direction and density variations that can affect cutting quality. Edge sealing considerations become important for applications exposed to moisture, while the flammability of MDF requires appropriate ventilation and safety measures during cutting. The excellent machinability of MDF allows for complex three-dimensional assemblies that leverage laser cutting precision for joint fitting and alignment features.
Quick Takeaways
- Laser cutting technology offers unmatched precision and versatility for both industrial and creative applications across diverse materials
- CO2 lasers excel at organic materials like MDF and textiles, while fiber lasers provide superior performance for metal cutting applications
- Material selection significantly impacts cutting quality, speed, and cost—understanding material properties ensures optimal results
- Australian laser cutting services vary in capabilities and specializations, with major cities offering advanced equipment and specialized expertise
- Proper design optimization can reduce costs by 20-40% through improved material utilization and reduced cutting time
- Quality certifications and industry experience are reliable indicators of service provider capability and reliability
- Regional considerations including climate, industry focus, and logistics affect service selection and project success
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Industry Applications and Case Studies
Automotive Industry Laser Cutting
The automotive industry represents one of the largest consumers of laser cutting technology, utilizing these systems for everything from precision body panels to intricate interior components. Modern vehicle manufacturing relies on laser cutting for airbag covers, where precise perforations ensure proper deployment while maintaining aesthetic appeal. The ability to cut complex curves and maintain tight tolerances makes laser cutting essential for modern automotive design requirements.
Electric vehicle manufacturing has driven innovation in laser cutting applications, particularly for battery enclosures and lightweight structural components. The precision required for safety-critical components like battery housings demands the accuracy that only laser cutting can provide. Advanced high-strength steels and aluminum alloys used in modern vehicles require the sophisticated cutting capabilities that fiber laser systems deliver.
Automotive interior components benefit significantly from laser cutting precision, enabling seamless integration of electronic components and complex ventilation systems. Dashboard assemblies, door panels, and seat components often incorporate laser-cut elements that would be impossible to manufacture economically using traditional methods. The consistency of laser cutting ensures perfect fitment across thousands of vehicles in production.
Aerospace and Defense Applications
Aerospace applications demand the highest standards of precision and quality, making laser cutting an indispensable technology for aircraft manufacturing. Laser cutting offers various advantages over more traditional approaches — it prevents work hardening, applies minimal heat to the metal, and often necessitates no finishing processes. This capability is crucial for aerospace components where material properties must remain uncompromised throughout the manufacturing process.
Titanium and exotic alloy processing represents a specialized segment where laser cutting technology excels. The biocompatibility and strength-to-weight ratio of titanium make it ideal for both aerospace and medical applications, while the precision of laser cutting enables complex geometries essential for lightweight structures. Defense applications often require materials and cutting capabilities that push the boundaries of current laser technology.
Satellite and space exploration equipment rely on laser cutting for components ranging from solar panel frames to instrument housings. The vacuum environment and extreme temperature variations of space applications demand materials and manufacturing processes that maintain integrity under harsh conditions. Laser cutting's minimal heat-affected zone and precise dimensional control make it ideal for space-qualified components.
Medical Device Manufacturing
Medical device manufacturing leverages laser cutting technology for applications ranging from surgical instruments to implantable devices. The biocompatibility requirements of medical applications often necessitate stainless steel grades that respond excellently to laser cutting processes. Laser cutting stainless steel for medical applications requires strict quality controls and documentation to meet regulatory requirements.
Microfluidic devices and laboratory equipment benefit from the precision capabilities of modern laser systems. The ability to create features at the microscale enables innovative medical diagnostic equipment and drug delivery systems. Clean room compatibility and validation requirements make laser cutting an attractive manufacturing option for regulated medical device production.
Custom orthopedic implants represent a growing application area where laser cutting enables patient-specific solutions. The biocompatibility of titanium combined with laser cutting precision allows for implants tailored to individual patient anatomy. This personalization capability represents the future of medical device manufacturing, where mass customization meets regulatory compliance requirements.
Online Laser Cutting Services and Digital Manufacturing
The Rise of Online Laser Cutting Platforms
Laser cutting online services have revolutionized access to professional manufacturing capabilities, enabling small businesses and individuals to access industrial-grade equipment without significant capital investment. These platforms combine automated quoting systems with sophisticated nesting algorithms to provide instant pricing and delivery estimates. The convenience of uploading CAD files and receiving finished parts within days has democratized access to precision manufacturing.
Digital manufacturing platforms integrate laser cutting with other processes such as bending, welding, and finishing to provide complete part solutions. The automation of order processing, production scheduling, and quality control enables consistent results at competitive prices. Online sheet metal fabrication service. Get custom parts delivered in just a few days—upload STEP or DXF files for instant pricing! This level of service accessibility has transformed how businesses approach prototyping and low-volume production.
Quality assurance in online laser cutting relies on sophisticated software verification and standardized processes that ensure consistent results across distributed production facilities. Digital work instructions and automated inspection systems maintain quality standards while reducing lead times. The traceability provided by digital systems enables rapid response to quality issues and continuous improvement of manufacturing processes.
Advantages and Limitations of Online Services
Online laser cutting services excel in standardized applications where material specifications and quality requirements are well-defined. The economies of scale achieved through automated processing and optimized nesting can result in significantly lower costs compared to traditional job shops. Rapid prototyping capabilities enable design iteration cycles that accelerate product development timelines.
However, specialized applications or custom materials may require the expertise and flexibility that traditional service providers offer. Complex assemblies, secondary operations, and specialized quality requirements often benefit from direct communication with experienced technicians. The choice between online and traditional services depends on project complexity, volume requirements, and timeline constraints.
Geographic considerations remain important even for online services, as shipping costs and delivery times can impact project economics. Australian-based online services offer advantages in terms of reduced shipping costs and faster delivery compared to international providers, while maintaining competitive pricing through operational efficiency and automation.
Understanding Laser Cutting Costs and Pricing
Factors Affecting Laser Cutting Costs
Material costs represent the largest component of most laser cutting projects, with material type, thickness, and sheet utilization directly impacting final pricing. We take all the custom metal parts in your order and "nest" them on sheet metal, to get the best material price. Efficient nesting can reduce material costs by 20-40% compared to inefficient layouts, making design optimization crucial for cost-effective production.
Cutting time depends on material thickness, cutting speed, and complexity of the geometry. Intricate designs with many small features require more cutting time than simple shapes, while thick materials reduce cutting speeds significantly. The type of laser system also affects cutting speed, with fiber lasers typically offering faster cutting speeds for metals compared to CO2 systems.
Setup and programming costs become significant factors for small quantities, while large production runs benefit from economies of scale that reduce per-part costs substantially. Rush orders and special requirements such as specific edge finishes or tight tolerances may incur additional charges. Understanding these cost drivers enables better project planning and budget management.
Comparing Service Provider Pricing
Pricing structures vary significantly between service providers, with some charging by cutting time, others by material area, and many using hybrid models that combine multiple factors. Understanding the pricing methodology helps evaluate quotes accurately and identify the most cost-effective provider for specific applications. Volume discounts and long-term contracts can provide significant savings for recurring production requirements.
Geographic location affects pricing through differences in labor costs, overhead expenses, and competition levels. Metropolitan areas typically offer more competitive pricing due to higher competition, while regional providers may offer lower overhead costs that offset transportation expenses. International providers may offer attractive pricing, but shipping costs and delivery times often eliminate potential savings.
Value-added services such as deburring, powder coating, and assembly can significantly impact total project costs. Some providers offer integrated services that reduce handling and coordination overhead, while others specialize in specific processes. Evaluating total cost of ownership rather than just cutting costs provides a more accurate comparison between service providers.
Future Trends in Laser Cutting Technology
Emerging Technologies and Innovations
Artificial intelligence and machine learning are revolutionizing laser cutting through predictive maintenance, process optimization, and automated quality control. Smart laser systems can adjust cutting parameters in real-time based on material conditions and cut quality feedback, reducing waste and improving consistency. These advances promise to make laser cutting more accessible and reliable for a broader range of applications.
Advanced beam shaping and multi-beam systems enable simultaneous cutting of multiple parts or processing of different materials within the same setup. These innovations increase productivity while maintaining the precision and quality advantages of laser cutting technology. Developments in laser source technology continue to improve efficiency and reduce operating costs across all laser types.
Integration with additive manufacturing creates hybrid systems that combine cutting and building capabilities in single machines. This convergence enables new manufacturing approaches that leverage the strengths of both technologies, particularly for complex assemblies and repair applications. The ability to add material through 3D printing and precisely remove material through laser cutting opens new possibilities for part design and manufacturing.
Environmental Considerations and Sustainability
Environmental sustainability becomes increasingly important in manufacturing decisions, with laser cutting offering several advantages over traditional cutting methods. The precision of laser cutting reduces material waste, while the elimination of consumable cutting tools reduces ongoing environmental impact. Energy efficiency improvements in laser technology continue to reduce the carbon footprint of laser cutting operations.
Recycling and material recovery programs help minimize the environmental impact of laser cutting waste. The clean cuts produced by laser systems often enable easier recycling of metal offcuts compared to mechanically cut materials. Sustainable material choices and local sourcing strategies further reduce the environmental impact of laser cutting projects.
Regulatory requirements and customer expectations drive continued improvements in environmental performance of laser cutting operations. Investment in renewable energy sources and energy-efficient equipment helps service providers meet sustainability goals while potentially reducing operating costs. The long-term trend toward sustainable manufacturing practices favors laser cutting technology due to its inherent efficiency advantages.
Getting Started with Your Laser Cutting Project
Project Planning and Preparation
Successful laser cutting projects begin with clear requirements definition including material specifications, dimensional tolerances, quantity requirements, and delivery timelines. Creating detailed drawings or CAD files with appropriate annotations ensures accurate communication with service providers and reduces the likelihood of errors or misunderstandings. Consider secondary operations such as deburring, finishing, or assembly during the planning phase to avoid delays later in the project.
Material selection requires balancing performance requirements, cost considerations, and manufacturing constraints. Consult with service providers early in the design process to understand material capabilities and limitations. Standard material grades and thicknesses typically offer better availability and pricing compared to exotic materials or non-standard sizes.
Prototype development allows validation of design concepts before committing to larger production quantities. Many laser cutting services offer expedited prototype services that enable rapid design iteration. Testing fit, function, and appearance with prototypes can prevent costly changes during production runs.
Working with Service Providers
Effective communication with laser cutting service providers ensures project success and helps build long-term relationships that benefit future projects. Provide complete technical requirements including material specifications, tolerances, surface finish requirements, and any special handling needs. Clear documentation reduces the risk of errors and enables accurate quotations.
Quality requirements should be established upfront, including inspection methods, acceptance criteria, and documentation needs. Discuss quality control procedures and certifications to ensure the service provider can meet your requirements. Regular communication during production helps identify and resolve issues before they impact delivery schedules.
Building relationships with reliable service providers creates value beyond individual projects through priority scheduling, technical support, and competitive pricing. Long-term partnerships enable service providers to invest in understanding your specific requirements and developing optimized processes that benefit both parties.
Frequently Asked Questions
What materials can be laser cut?
Laser cutting works with a wide variety of materials including metals (steel, stainless steel, aluminum, copper, brass), non-metals (MDF, plywood, acrylic, leather, textiles), and specialized materials (ceramics, composites). The specific materials depend on the laser type and service provider capabilities. CO2 lasers excel with organic materials while fiber lasers are optimized for metals.
How accurate is laser cutting?
Modern laser cutting systems typically achieve tolerances of ±0.1mm to ±0.25mm depending on material thickness and cutting conditions. Thinner materials generally allow tighter tolerances, while thicker sections may require larger tolerance allowances. The accuracy also depends on proper machine maintenance and operator expertise.
What file formats are required for laser cutting?
Most laser cutting services accept DXF, DWG, and AI vector formats. Some providers also accept PDF files with vector graphics. Ensure your files include proper dimensions, layer organization, and cutting instructions. Raster formats like JPG or PNG are not suitable for cutting applications but may be used for engraving reference.
How much does laser cutting cost?
Laser cutting costs vary significantly based on material type, thickness, complexity, and quantity. Simple parts in thin steel might cost a few dollars each, while complex thick parts could cost significantly more. Material costs, cutting time, and setup charges all contribute to final pricing. Request quotes from multiple providers for accurate cost comparison.
What's the difference between laser cutting and other cutting methods?
Laser cutting offers superior precision, clean cut edges, and minimal material distortion compared to mechanical cutting methods. Unlike plasma or waterjet cutting, laser cutting produces very narrow kerfs and excellent edge finish. The non-contact process eliminates tool wear and enables cutting of delicate materials that mechanical methods cannot handle effectively.
Conclusion: Maximizing the Benefits of Laser Cutting Technology
Laser cutting technology has fundamentally transformed modern manufacturing, offering unprecedented precision, versatility, and efficiency across diverse applications and industries. The evolution from early CO2 systems to advanced fiber laser technology continues to expand capabilities while reducing costs, making professional-grade laser cutting accessible to businesses of all sizes. Whether you're exploring laser cutting services near me for prototype development or considering investment in your own equipment for production applications, understanding the capabilities and limitations of different laser technologies ensures optimal results.
The Australian laser cutting industry reflects global trends toward specialization and service excellence, with providers in major cities like Sydney and Brisbane offering world-class capabilities that serve both domestic and export markets. The growth of online laser cutting platforms has democratized access to professional manufacturing services, enabling small businesses and individual makers to leverage industrial-grade equipment for their projects. This accessibility, combined with the precision and quality advantages of laser cutting, positions the technology as a cornerstone of modern digital manufacturing.
Success in laser cutting projects depends on understanding the interplay between material properties, design requirements, and manufacturing capabilities. Proper planning, clear communication with service providers, and attention to design optimization can result in significant cost savings while ensuring quality outcomes. As laser technology continues to evolve with artificial intelligence integration and improved energy efficiency, the future promises even greater capabilities and broader applications for this transformative manufacturing technology.
The key to maximizing laser cutting benefits lies in matching technology capabilities with specific application requirements, whether that involves selecting the right service provider, optimizing designs for manufacturing efficiency, or choosing appropriate materials for the intended use. By understanding these fundamental principles and staying informed about technological developments, businesses and individuals can harness the full potential of laser cutting to achieve their manufacturing objectives efficiently and cost-effectively.
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References and Additional Resources
- Australian Laser Cut - Quality laser cutting and etching services. Retrieved from https://www.auslasercut.com.au/
- SendCutSend - Stainless Steel Laser Cutting specifications and applications. Retrieved from https://sendcutsend.com/materials/stainless-steel/
- Xometry - Effective Laser Cutting for Stainless Steel. Retrieved from https://www.xometry.com/resources/sheet/laser-for-cutting-stainless-steel/
- OSH Cut - Custom metal cutting and nesting services. Retrieved from https://www.oshcut.com/
- Industry research and technical specifications compiled from multiple laser cutting equipment manufacturers and service providers across Australia