Striving for perfect laser cutting results (high precision, high efficiency) but often troubled by burrs and poor cutting surfaces? SNSTC addresses these core challenges, analyzes the root causes in depth, and provides practical optimization solutions to help you break through cutting quality bottlenecks. We strongly recommend saving this article as your exclusive “solution handbook” for laser cutting problems!

一、Rough Edges and Burrs

1.Cause Analysis

①Improper laser power setting: Too low power prevents full material melting, resulting in rough cutting surfaces.

②Excessive cutting speed: Insufficient beam interaction time causes incomplete melting or vaporization, leading to burrs.

③Focus offset: The laser focal point deviates from the optimal working position (typically on or slightly below the material surface), reducing energy density and cutting accuracy.

④Abnormal assist gas pressure: Insufficient pressure fails to remove molten slag, while excessive pressure disturbs the molten pool—both leading to burrs.

⑤Mismatch between process parameters and material properties: Key parameters (e.g., power, speed) are not optimized based on material type, thickness, etc.

⑥Contaminated laser-head optics: Dirt or spatter on lenses attenuates or scatters the beam, lowering cut quality.

2.Solutions

①Recalibrate laser power: Adjust appropriately to ensure full penetration and stable cutting.

②Optimize cutting speed: Reduce speed to provide sufficient laser dwell time for complete melting, eliminating uncut areas.

③Precisely calibrate and dynamically monitor focal length: Ensure the laser focus is accurately positioned on the material surface or preset penetration depth.

④Adjust and stabilize auxiliary gas pressure: Set optimal pressure based on material properties (e.g., melting point, thickness) and maintain stable airflow.

⑤Match parameters to material properties: Study material attributes thoroughly and set core process parameters (e.g., power, speed, pressure) accordingly (e.g., by building a parameter database).

⑥Strictly implement laser head cleaning: Regularly remove contaminants and slag from the protective lens and nozzle to ensure beam transmission quality.

二、Overly Wide Cut or Excessive Melting

1.Cause Analysis

①Excessive laser power: Too high power causes excessive heat absorption, surpassing the required melting volume and leading to molten pool instability.

②Cutting speed too slow: Prolonged laser action per unit area accumulates heat input, significantly expanding the heat-affected zone (HAZ).

③Focus offset: The laser focal point deviates from the optimal working position. This increases the laser beam diameter, reduces energy density, lowers melting efficiency, and expands the heat-affected zone (HAZ).

④Insufficient auxiliary gas flow: Inadequate airflow fails to effectively blow away molten metal, causing accumulation or re-solidification in the kerf and worsening melting.

⑤Mismatch between material properties/thickness and process: Specific materials (such as high thermal conductivity or high reflectivity) or thick materials with complex thermal conduction are prone to excessive melting.

⑥Laser beam quality degradation: Poor beam mode (e.g., non-fundamental mode), excessive divergence angle, or uneven energy distribution prevents effective energy concentration for cutting, generating excess heat.

2.Solutions

①Optimize laser power setting: Adjust precisely according to material type and thickness, keeping it at the threshold to prevent excessive melting.

②Increase cutting speed: Increase the cutting rate to reduce heat input per unit area and control the size of the heat-affected zone.

③Accurately adjust and monitor focal position: Keep the laser focus at the optimum location to sustain high energy density.

④Increase and stabilize assist gas flow: Ensure sufficient and stable airflow to effectively remove molten material, preventing overheating of the melt pool and accumulation of molten metal

⑤Precisely match material and process parameters: Optimize key parameter combinations (power, speed, gas pressure, etc.) for specific materials—especially melt-prone or thick plates—by building or referencing a material-process database.

⑥Maintain and optimize laser beam quality: 

Regularly clean and calibrate the optical system (lenses, nozzle).

Perform beam diagnostics and mode optimization according to equipment requirements (e.g., using a beam profiler).

Ensure stable laser operation and maintain beam quality within specified standards.

三、Uneven Cut Surface with Ripples

1.Cause Analysis

①Unstable laser power output: Dynamic fluctuations in laser power cause uneven energy absorption by the material, affecting cutting consistency.

②Fluctuating cutting speed: Feed rate variations alter laser dwell time per unit length, causing uneven heat input. 

③Focal offset: Deviation from the set focal position alters laser energy density, directly affecting cutting precision and surface quality.

④Poor material condition: Warping or uneven surfaces cause variations in nozzle-to-material distance, leading to cutting path deviation.

⑤Mechanical vibration of laser head: Insufficient rigidity or drive-system backlash causes vibration, leading to laser beam misalignment.

⑥Fluctuating auxiliary gas flow: Instability in pressure or flow leads to inconsistent molten material removal, degrading cut surface quality.

2.Solutions

①Stabilize laser power output:

Set and lock upper/lower power limits.

Ensure stable laser operation (cooling, power supply)

Use closed-loop power feedback control.(Optional)

②Ensure constant cutting speed：

Optimizing motion control parameters (acceleration, jerk), 

Avoiding sharp turns or sudden speed changes in paths

Keeping guide rails and gear racks clean and well-lubricated.

③Precisely calibrate and monitor focal position:

Perform regular focus calibration, apply auto-focus systems (e.g. capacitive height tracking)

Ensure sensor sensitivity and reliability.

④Ensure material flatness and stability

Level the material before cutting

Secure the material firmly to the table using magnetic or vacuum fixtures to eliminate warping.

⑤Eliminate laser head vibration sources

Check and tighten all mechanical connections (screws, couplings). 

Eliminate transmission gaps; ensure rail sliders are secure.

Assess and improve equipment base rigidity.

⑥Stabilize auxiliary gas supply:

Use high-quality pressure regulators and flow meters for accurate settings.

Check gas path sealing; eliminate leaks.

Ensure sufficient and stable gas source pressure.

四、 Abnormal Sparks During Cutting

1.Cause Analysis

①Laser power setting exceeds limits: Excessively high power causes the material to absorb too much thermal energy, destabilizing the molten pool and triggering intense sparks.

②Improper cutting speed matching: Too low feed rate results in continuous accumulation of laser energy in localized areas, with excessive heat input exacerbating spark outbursts. 

2.Solutions

①Precisely calibrate laser power: Adjust power according to material thickness and properties (e.g., reflectivity, melting point), keeping it close to the critical melting threshold to suppress excessive thermal reactions.

②Dynamically optimize cutting speed: Increase feed rate to maintain thermal balance, shorten dwell time per unit area, and ensure controlled spark generation.

Most laser-cutting quality issues stem from deviations in process parameters, inadequate adaptation to material characteristics, or insufficient equipment maintenance. By precisely adjusting laser power, cutting speed, focal position, and optimizing assist-gas flow, cutting accuracy and edge quality can be significantly improved.

If you encounter specific application issues, please feel free to contact our after-sales technical support team. We will provide you with professional and efficient solutions.