How Does a Laser Cutting Machine Work in Industries

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Alex Carter
·December 1, 2024
·23 min read
How
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Laser cutting machines have transformed industrial manufacturing by offering unmatched precision and efficiency. But how does a laser cutting machine work? These machines generate a highly focused laser beam that melts, burns, or vaporizes materials to create clean and accurate cuts. Unlike traditional cutting tools, laser cutters excel in handling intricate designs and diverse materials, including metals, plastics, and wood. Their ability to minimize waste while maintaining high precision has made them indispensable in industries like automotive, aerospace, and electronics. With advancements in technology, laser cutting continues to optimize production processes, ensuring faster turnaround times and superior quality.

Key Takeaways

  • Laser cutting machines utilize focused laser beams to achieve high precision and efficiency in cutting various materials, including metals, plastics, and wood.
  • The cutting process involves melting, burning, or vaporizing materials, allowing for intricate designs and minimal waste, making laser cutting a cost-effective solution.
  • Advanced control systems and software enable precise programming of complex patterns, ensuring consistent quality across high-volume production runs.
  • Laser cutting is versatile, suitable for diverse industries such as automotive, aerospace, and medical, enhancing production capabilities and innovation.
  • Despite high initial investment costs, the long-term benefits of reduced waste and energy consumption make laser cutting machines a valuable asset for manufacturers.
  • Emerging technologies, including automation and AI, are set to further enhance the efficiency and adaptability of laser cutting processes in the future.

How Does a Laser Cutting Machine Work

How
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Laser cutting machines operate with remarkable precision, transforming industrial manufacturing processes. To understand their functionality, you need to explore three key aspects: generating the laser beam, the cutting process, and the role of optics in achieving precision.

Generating the Laser Beam

The process begins with the generation of a high-powered laser beam. This beam is created by amplifying light through a laser source, such as CO2, fiber, or Nd:YAG lasers. Each type of laser source has unique characteristics:

  • CO2 lasers excel in cutting non-metal materials like wood, plastic, and fabric.
  • Fiber lasers are highly efficient for cutting metals, including steel and aluminum.
  • Nd:YAG lasers are ideal for applications requiring extreme precision, such as in the medical and electronics industries.

The laser beam is then directed through a series of mirrors and lenses to focus its energy on a specific point. This focused beam generates intense heat, which is essential for cutting through materials with precision.

The Cutting Process: Melting, Burning, and Vaporizing

Once the laser beam reaches the material, the cutting process begins. The intense heat from the laser interacts with the material in one of three ways:

  1. Melting: The laser melts the material at the focal point, creating a clean edge. This method is commonly used for metals.
  2. Burning: For materials like wood or fabric, the laser burns through the surface, leaving a precise cut.
  3. Vaporizing: In some cases, the laser vaporizes the material entirely, producing intricate designs without physical contact.

The entire process is controlled by computer numerical control (CNC) technology, which ensures accuracy and consistency. CNC systems allow you to program complex patterns and shapes, making laser cutting suitable for detailed designs.

The Role of Optics and Focus in Achieving Precision

Optics play a crucial role in determining the quality of the cut. The laser beam passes through specialized lenses that focus it into a fine point. This focused beam delivers maximum energy to a small area, enabling precise cuts even on intricate designs.

Proper focus is essential for achieving the desired results. If the beam is not correctly aligned, the cut may lack sharpness or accuracy. Advanced laser cutting machines use automated systems to adjust the focus based on the material's thickness and type. This ensures consistent performance across various applications.

By understanding these core principles, you can appreciate how laser cutting machines achieve such high levels of precision and efficiency. Their ability to handle diverse materials and complex designs makes them indispensable in modern industries.

Core Components of a Laser Cutting Machine

Understanding the core components of a laser cutting machine helps you grasp how these machines achieve their remarkable precision and efficiency. Each part plays a vital role in ensuring smooth operation and delivering high-quality results.

Laser Source: CO2, Fiber, and Nd:YAG Lasers

The laser source is the heart of any laser cutting machine. It generates the powerful beam that cuts through materials. The three primary types of laser sources—CO2, fiber, and Nd:YAG—each serve specific purposes:

  • CO2 lasers are ideal for non-metal materials like wood, acrylic, and fabric. They are widely used in industries requiring intricate designs on softer materials.
  • Fiber lasers excel in cutting metals such as steel, aluminum, and brass. Their efficiency and durability make them a popular choice for heavy-duty industrial applications.
  • Nd:YAG lasers specialize in tasks demanding extreme precision. You’ll often find them in the medical and electronics industries, where accuracy is critical.

Each laser type uses unique methods to amplify light and focus energy. For instance, fiber lasers direct light through fiber optics to intensify the beam before it interacts with the material. This diversity allows you to choose the right laser source based on your specific needs.

Control Systems and Software for Precision

Control systems and software are the brains behind a laser cutting machine. These systems manage the movement of the laser beam and ensure precise cuts. Most machines rely on computer numerical control (CNC) technology, which allows you to program detailed patterns and shapes.

Modern laser cutting machines come equipped with advanced software that simplifies the design process. You can upload digital files directly into the system, enabling seamless transitions from design to production. The software also adjusts settings like speed, power, and focus based on the material type. This automation ensures consistent results and reduces the risk of errors.

Cutting Bed and Material Handling Mechanisms

The cutting bed provides a stable surface for materials during the cutting process. It is designed to handle various sizes and thicknesses, ensuring versatility. Some cutting beds feature adjustable heights, allowing you to work with materials of different dimensions.

Material handling mechanisms enhance efficiency by automating the loading and unloading process. Features like conveyor belts and robotic arms reduce manual labor and speed up production. These mechanisms are especially useful in high-volume manufacturing environments, where time is a critical factor.

By combining a robust laser source, intelligent control systems, and efficient material handling, laser cutting machines deliver unparalleled performance. These components work together to ensure that every cut meets your exact specifications, no matter the complexity of the design.

Advantages of Laser Cutting Machines in Industries

Laser cutting machines have revolutionized industrial processes by offering unmatched benefits. These advantages make them a preferred choice across various industries, from automotive to electronics. Let’s explore how these machines enhance precision, efficiency, and versatility.

High Precision and Accuracy for Complex Designs

Laser cutting machines excel in delivering precise and accurate cuts, even for intricate designs. The focused laser beam ensures minimal deviation, allowing you to achieve clean edges and detailed patterns. Unlike traditional cutting methods, laser cutting eliminates physical contact with the material. This non-contact process reduces the risk of contamination and ensures consistent results.

For example, when compared to plasma cutting, laser cutting provides superior precision and dimensional accuracy. It handles complex shapes and intricate geometries with ease, making it ideal for industries like jewelry and medical device manufacturing. You can rely on laser cutting to produce components that meet exact specifications without the need for secondary finishing.

Speed and Efficiency in High-Volume Production

Speed is a critical factor in modern manufacturing, and laser cutting machines deliver exceptional performance. These machines operate at high speeds, enabling you to complete large-scale production runs in less time. The integration of computer numerical control (CNC) technology further enhances efficiency by automating the cutting process.

Compared to other methods like waterjet or mechanical cutting, laser cutting stands out for its faster processing times. It minimizes downtime by reducing the need for tool changes or adjustments. This efficiency makes laser cutting an excellent choice for industries requiring high-volume production, such as automotive and aerospace.

Additionally, laser cutting consumes less energy than plasma cutting, resulting in lower operational costs. By optimizing production speed and energy usage, you can achieve significant cost savings while maintaining high-quality output.

Versatility Across a Wide Range of Materials

One of the most remarkable features of laser cutting machines is their versatility. These machines can cut through a wide variety of materials, including metals, plastics, wood, and fabrics. Whether you need to process thin sheets of aluminum or intricate acrylic designs, laser cutting adapts to your requirements.

Different laser sources, such as CO2 and fiber lasers, enhance this versatility. For instance:

  • CO2 lasers are perfect for non-metal materials like wood and fabric.
  • Fiber lasers excel in cutting metals like steel and brass.

This adaptability allows you to use laser cutting machines across diverse industries. From creating custom signage in advertising to shaping lightweight components in aerospace, the possibilities are endless. Moreover, the ability to handle multiple materials reduces the need for additional equipment, streamlining your operations.

By combining precision, speed, and versatility, laser cutting machines offer unparalleled advantages. These benefits not only improve production efficiency but also open up new opportunities for innovation in design and manufacturing.

Cost-Effectiveness Through Reduced Waste

Laser cutting machines stand out as a cost-effective solution in industrial manufacturing due to their ability to minimize material waste. Unlike traditional cutting methods, which often leave behind significant scrap material, laser cutting ensures precise cuts with minimal excess. This precision reduces the amount of raw material you need, ultimately lowering production costs.

The non-contact nature of laser cutting plays a key role in waste reduction. The laser beam interacts directly with the material without applying physical force. This eliminates issues like warping or distortion, which are common in mechanical cutting methods. You can achieve clean edges and intricate designs without compromising the integrity of the material.

Laser cutting also excels in optimizing material usage. Advanced software allows you to nest multiple designs on a single sheet of material. This nesting process maximizes the use of available space, ensuring that every inch of the material contributes to the final product. For industries dealing with expensive materials like metals or composites, this feature significantly reduces costs.

When compared to other cutting methods, laser cutting offers distinct advantages in waste management:

  • Plasma cutting often generates more waste due to its lower precision and inability to handle intricate designs.
  • Waterjet cutting produces slurry waste, which requires additional cleanup and disposal efforts.
  • Mechanical cutting methods like sawing or milling leave behind larger amounts of scrap material and require secondary finishing.

By choosing laser cutting, you not only reduce material waste but also save on energy costs. Laser cutting machines consume less energy than plasma cutters, making them a more sustainable option. Additionally, the reduced need for secondary processes, such as sanding or polishing, further lowers operational expenses.

Incorporating laser cutting into your production process allows you to achieve high-quality results while maintaining cost efficiency. The combination of precision, material optimization, and energy savings makes laser cutting an invaluable tool for modern industries striving to balance quality with affordability.

Applications of Laser Cutting Machines Across Industries

Applications
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Laser cutting machines have become essential tools across various industries. Their ability to deliver precision, efficiency, and versatility makes them invaluable for diverse applications. Let’s explore how these machines are transforming key sectors.

Automotive Industry

Cutting and Shaping Metal Components

In the automotive industry, laser cutting machines play a crucial role in shaping and cutting metal components. You can use them to create precise parts for car bodies, chassis, and engine components. The high precision of laser cutting ensures that every piece fits perfectly, reducing assembly errors. Unlike traditional methods, laser cutting minimizes material waste, which lowers production costs. This efficiency makes it an ideal choice for high-volume manufacturing.

"Metal laser cutters are highly cost-effective due to low operating costs and minimal material waste."

By adopting laser cutting, you can streamline production processes and achieve consistent quality in every component.

Creating Custom Interior Designs

Laser cutting machines also excel in crafting custom interior designs for vehicles. You can use them to cut intricate patterns on materials like leather, fabric, or plastic. This capability allows manufacturers to offer personalized options for car interiors, enhancing customer satisfaction. The non-contact nature of laser cutting ensures clean edges without damaging delicate materials. This precision eliminates the need for additional finishing processes, saving both time and money.

Aerospace Industry

Manufacturing Lightweight and Durable Parts

The aerospace industry demands lightweight yet durable components, and laser cutting machines meet this requirement with ease. You can use them to cut materials like titanium and aluminum, which are essential for aircraft construction. The precision of laser cutting ensures that parts meet strict safety and performance standards. By reducing material waste, laser cutting also helps lower production costs, which is critical in this high-stakes industry.

"Laser cutting offers numerous cost savings compared to plasma cutting, including reduced material costs, increased production speed, and less maintenance costs."

This efficiency makes laser cutting a preferred method for manufacturing aerospace components.

Ensuring Precision for Safety Standards

Safety is paramount in aerospace, and laser cutting machines help you achieve the required precision. These machines can produce complex geometries with tight tolerances, ensuring that every part meets regulatory standards. The use of advanced control systems allows you to maintain consistency across production runs. This reliability enhances the overall safety and performance of aircraft, making laser cutting an indispensable tool in the aerospace sector.

Medical Device Manufacturing

Producing Surgical Instruments and Stents

In the medical field, laser cutting machines are vital for producing surgical instruments and stents. You can rely on their precision to create tools with intricate designs and smooth edges, which are essential for medical procedures. The ability to cut small and complex shapes makes laser cutting ideal for manufacturing stents, which require extreme accuracy. This precision reduces the risk of errors, ensuring patient safety.

"Laser-cutting machines have numerous advantages, including reduced material waste, lower production costs, and increased productivity."

By using laser cutting, you can produce high-quality medical devices while optimizing costs.

Creating Custom Implants and Prosthetics

Laser cutting machines also enable the creation of custom implants and prosthetics. You can use them to cut materials like titanium and ceramics, which are commonly used in medical implants. The flexibility of laser cutting allows you to design implants tailored to individual patients, improving their comfort and functionality. This customization enhances the overall effectiveness of medical treatments, making laser cutting a valuable asset in healthcare.

Electronics Industry

Cutting Printed Circuit Boards (PCBs)

In the electronics industry, precision is critical. Laser cutting machines provide the accuracy needed to cut printed circuit boards (PCBs) with intricate designs. You can rely on these machines to create clean and precise cuts without damaging delicate components. The non-contact nature of laser cutting ensures that the material remains intact, reducing the risk of errors during production.

Laser cutting also eliminates the need for additional finishing processes. This saves you both time and money, especially when working with high-volume production. By using advanced control systems, you can program detailed patterns directly into the machine, ensuring consistency across multiple PCBs. This level of precision makes laser cutting an essential tool for modern electronics manufacturing.

Shaping Electronic Components

Laser cutting machines excel in shaping electronic components with complex geometries. You can use them to cut materials like silicon, ceramics, and thin metals, which are commonly used in electronic devices. The focused laser beam delivers high precision, allowing you to achieve intricate shapes that meet exact specifications.

The speed of laser cutting machines enhances productivity in electronics manufacturing. Unlike traditional methods, laser cutting minimizes downtime by reducing the need for tool changes. This efficiency helps you meet tight deadlines without compromising quality. Additionally, the reduced material waste lowers production costs, making laser cutting a cost-effective solution for shaping electronic components.

Advertising and Signage

Engraving and Cutting Acrylic for Signboards

In advertising, creating visually appealing signboards is crucial. Laser cutting machines allow you to engrave and cut acrylic with unmatched precision. You can produce intricate designs and sharp edges that enhance the overall appearance of your signage. The ability to work with various thicknesses of acrylic adds versatility to your projects.

Laser cutting avoids the use of physical tools, ensuring that the acrylic surface remains smooth and free from damage. This eliminates the need for secondary finishing, saving you valuable time and resources. Whether you’re crafting large outdoor signs or small indoor displays, laser cutting provides the flexibility and accuracy you need to bring your designs to life.

Creating Intricate Branding Designs

Branding often requires intricate designs that stand out. Laser cutting machines enable you to create detailed logos, patterns, and text with precision. You can use materials like wood, metal, or acrylic to produce unique branding elements that capture attention. The high level of detail achievable with laser cutting ensures that your designs maintain their quality, even at smaller scales.

By automating the cutting process, laser cutting machines help you complete projects faster. This efficiency allows you to take on more orders without sacrificing quality. Additionally, the reduced material waste ensures that you maximize your resources, making laser cutting an economical choice for branding applications.

Jewelry and Fashion

Crafting Intricate Jewelry Designs

In the jewelry industry, precision and detail are paramount. Laser cutting machines allow you to craft intricate designs with ease. You can use them to cut metals like gold, silver, and platinum, as well as non-metal materials like acrylic and leather. The focused laser beam ensures clean cuts, enabling you to create delicate patterns that traditional methods cannot achieve.

Laser cutting also enhances efficiency in jewelry production. You can program complex designs into the machine, ensuring consistency across multiple pieces. This automation reduces production time and minimizes material waste, helping you lower costs while maintaining high-quality output.

Engraving Patterns on Accessories

Accessories often feature engraved patterns that add a touch of elegance. Laser cutting machines provide the precision needed to engrave intricate designs on materials like metal, leather, and wood. You can customize patterns to suit individual preferences, making your accessories unique and appealing.

The non-contact nature of laser cutting ensures that the material remains undamaged during the engraving process. This eliminates the need for additional polishing or finishing, saving you time and effort. Whether you’re creating personalized gifts or mass-producing accessories, laser cutting offers the accuracy and efficiency you need to meet your goals.

Challenges and Limitations of Laser Cutting Machines

High Initial Investment Costs

Laser cutting machines require a significant upfront investment. The advanced technology, precision components, and software integration contribute to their high price. If you are considering adopting laser cutting for your business, you must evaluate whether the long-term benefits outweigh the initial expense. For small-scale operations or startups, this cost can be a barrier.

"India is dominating the demand for cutting machines due to the surging demand for automobiles and an increase in per capita income."

This highlights how industries with high production demands often justify the investment. However, for businesses with limited budgets, exploring leasing options or government subsidies might help mitigate the financial burden.

Limitations with Certain Materials

While laser cutting machines excel with many materials, they face challenges with specific ones. Reflective metals like copper and brass can cause issues. These materials reflect the laser beam, reducing efficiency and potentially damaging the machine. If you work with such materials, you may need specialized equipment or alternative cutting methods.

Additionally, some materials, such as certain plastics, release harmful fumes when cut with lasers. This requires you to invest in proper ventilation systems to ensure safety. Understanding the material compatibility of your laser cutter is essential to avoid operational inefficiencies or health hazards.

Maintenance and Operational Expertise Required

Operating a laser cutting machine demands technical expertise. You need skilled operators who understand the machine's software, settings, and maintenance requirements. Without proper training, errors can occur, leading to wasted materials or damaged equipment.

Regular maintenance is also crucial to keep the machine running efficiently. Components like lenses and mirrors require cleaning and alignment. Neglecting maintenance can result in reduced precision and costly repairs. If your team lacks the necessary expertise, you may need to hire specialists, adding to operational costs.

"Laser-cutting machines find dominant applications in the production lines of automotive and continuous manufacturing due to their capabilities, such as precision cuts, low production delays, and exceptional productivity."

This demonstrates the importance of maintaining these machines to achieve their full potential. By investing in training and routine upkeep, you can maximize the benefits of laser cutting while minimizing downtime and expenses.

The Future of Laser Cutting Technology in Industries

Advancements in Laser Technology

Laser cutting technology continues to evolve, offering you more precision and efficiency than ever before. Modern advancements focus on enhancing the power and accuracy of laser beams. For instance, fiber lasers now dominate the industry due to their ability to cut metals like steel and aluminum with unmatched precision. These lasers consume less energy, making them an eco-friendly choice for manufacturers.

New developments also include ultrafast lasers, which operate at incredibly high speeds. These lasers allow you to cut intricate designs on delicate materials without causing damage. Additionally, hybrid laser systems combine multiple laser types, giving you the flexibility to work with a broader range of materials. These innovations ensure that laser cutting remains a top choice for industries requiring high-quality results.

"Laser cutting finds application in many manufacturing industries because of the combination of versatility, high processing speeds, and precision."

This versatility ensures that as technology advances, laser cutting will continue to meet the growing demands of modern industries.

Integration with Automation and Artificial Intelligence

Automation and artificial intelligence (AI) are transforming the way you use laser cutting machines. Automated systems now handle tasks like material loading, unloading, and alignment, reducing the need for manual intervention. For example, automatic feeder shuttle tables allow you to process large volumes of sheet metal without constant monitoring. This feature increases productivity and lets you complete projects faster.

AI integration takes this efficiency even further. Smart laser cutting machines can analyze material properties and adjust settings like speed and intensity in real time. This adaptability ensures consistent quality across different materials and thicknesses. AI also enables predictive maintenance, alerting you to potential issues before they cause downtime. By embracing automation and AI, you can optimize your production processes and stay ahead in competitive markets.

Expanding Applications in Emerging Industries

The versatility of laser cutting technology opens doors to new applications in emerging industries. In electronics, for example, laser cutting plays a crucial role in producing precise components like circuit boards and microelectronics. You can use this technology to create intricate patterns and small-scale parts, meeting the demands of miniaturization and customization trends.

In the medical field, laser cutting enables the production of advanced surgical tools and implants. The precision of lasers ensures that these devices meet strict safety and performance standards. Similarly, industries like renewable energy and construction are adopting laser cutting for tasks like fabricating solar panels and cutting complex architectural designs.

"Laser cutting is an advanced cutting technology used by various industries like medical, jewelry, furniture, electronics, aerospace, agricultural, construction, etc."

This adaptability ensures that laser cutting remains relevant as industries evolve. By exploring these emerging applications, you can unlock new opportunities and drive innovation in your field.


Laser cutting machines have revolutionized industrial processes by combining precision, speed, and versatility. You now understand how a laser cutting machine works, from generating the laser beam to achieving intricate cuts with minimal waste. These machines have found applications across industries, including automotive, aerospace, and medical device manufacturing, showcasing their adaptability and efficiency. Despite challenges like high initial costs and material limitations, advancements in technology continue to expand their potential. As industries evolve, laser cutting technology holds the promise of reshaping manufacturing with innovative solutions and enhanced productivity.

FAQ

What is a laser cutting machine?

A laser cutting machine uses a high-powered laser beam to cut, engrave, or shape materials. The laser focuses intense energy on a specific point, melting, burning, or vaporizing the material. This process ensures precise and clean cuts, making it ideal for industries like automotive, aerospace, and electronics.

How does laser cutting differ from traditional cutting methods?

Laser cutting offers unmatched precision and efficiency compared to traditional methods. Unlike mechanical tools, lasers do not physically touch the material, reducing wear and tear. This non-contact process minimizes waste, ensures cleaner edges, and handles intricate designs with ease. Traditional methods often require secondary finishing, while laser cutting delivers ready-to-use results.

What materials can a laser cutting machine process?

Laser cutting machines work with a wide range of materials. These include metals like steel, aluminum, and titanium, as well as non-metals such as wood, acrylic, fabric, and plastics. The type of laser—CO2, fiber, or Nd:YAG—determines the machine's compatibility with specific materials.

Is laser cutting environmentally friendly?

Yes, laser cutting is considered environmentally friendly. It reduces material waste by optimizing cuts and eliminates the need for chemical treatments. Fiber lasers, in particular, consume less energy compared to other cutting methods. This efficiency contributes to sustainable manufacturing practices.

Can laser cutting machines handle high-volume production?

Laser cutting machines excel in high-volume production. Their speed and automation capabilities allow you to complete large-scale projects quickly. Features like CNC technology ensure consistent quality across multiple units, making them ideal for industries requiring mass production.

Are there any limitations to using laser cutting machines?

Laser cutting machines face challenges with reflective materials like copper and brass, which can reflect the laser beam and reduce efficiency. Additionally, some plastics release harmful fumes during cutting, requiring proper ventilation systems. High initial costs and the need for skilled operators are also considerations.

How does laser cutting benefit the medical industry?

Laser cutting has revolutionized the medical field. It enables the production of precise surgical instruments, stents, and custom implants. The non-invasive nature of lasers ensures smooth edges and intricate designs, essential for medical applications. This technology also supports advancements in diagnostics and treatments.

"Laser technology has transformed medicine, enabling non-invasive treatments and precise surgeries."

What role does automation play in laser cutting?

Automation enhances the efficiency of laser cutting machines. Automated systems handle tasks like material loading and alignment, reducing manual labor. AI integration allows machines to adjust settings in real time, ensuring consistent quality. These advancements improve productivity and reduce operational costs.

How has laser technology advanced over the years?

Laser technology has seen significant advancements. Modern lasers, such as fiber lasers, offer higher precision and energy efficiency. Ultrafast lasers enable intricate cuts on delicate materials without damage. Hybrid systems combine multiple laser types, expanding their applications across industries like healthcare, manufacturing, and renewable energy.

"From healthcare to manufacturing, lasers have become an integral part of daily life, pushing the boundaries of innovation."

What is the future of laser cutting technology?

The future of laser cutting lies in further integration with automation and artificial intelligence. Smart systems will enhance adaptability and predictive maintenance. Emerging industries, such as renewable energy and microelectronics, will continue to adopt laser cutting for its precision and versatility. These advancements promise to reshape manufacturing and open new possibilities.

See Also

Understanding Laser Cutting Machines And Their Various Types

The Process Behind Machines Cutting Metal Like Paper

Essential Features To Know About Waterjet Cutting Machines

Exploring CNC Cutting Machines And Their Different Varieties

Guidelines For Selecting The Ideal Water Jet Cutting Machine