Compressed Air Cutting Benefits and Limitations

When it comes to precision cutting, industries across the globe are constantly seeking methods that ensure accuracy, speed, and cost-efficiency. One of the innovative techniques gaining traction is compressed air cutting. In laser beam cutting, the gas plays a major role in making the material to eject through the beam kerf path. Gas used in laser beam cutting is often named as “Assist gas”. Based on the application, sometimes reactive gas is used (Oxygen, O2) and sometimes non-reactive gas / inert gas is used (like Nitrogen (N2) / Argon (Ar). 

Also Read Us: What is a Flame or Flashback Arrestor? How it Works?

What is Compressed Air Cutting?

Compressed air cutting involves using pressurized air to drive a cutting tool, such as a nozzle, to cut through materials. This technique is commonly used in industries where precision cutting of softer materials like foam, rubber, or plastics is required. The cutting tool is powered by compressed air that provides the necessary force to achieve clean, efficient cuts without causing material deformation.

Role of Assist gas

The functions of assist gas during laser cutting are as follows

To maintain the constant material removal by uniformly involving into the process

1. To involve in the reaction if reactive gas is used (Exothermic reaction)
2. To blow out the melt if inert gas is used (Fusion Cutting)

Purpose of Compressed Air cutting

Compressed Air is a commonly used gas in any industry. So far, air has come across a wide range of applications starting from loading and lifting to cleaning and dusting. To emphasize on the part of thermal cutting, still in plasma, compressed air is used in cutting mild steel. With a compressor, there is no need for a power tool, a pneumatic one can do the job just as well, if not better. Bringing multiple benefits to the domestic and professional user, from hammering and sawing to spray-painting and tyre inflation, compressed air is easy to use and can boost productivity. The major reason behind that is as follows

1. This is available abundantly
2. Cost of acquiring this is very low
3. There is already a compressed air generator available in 99% of industries
4. There is no waiting time and no supply chain involved

5. There is Shortage of Oxygen and Nitrogen due to Pandemic and it is the major reason for all customers switching to Air cutting from Oxygen , Nitrogen cutting

Benefits of Compressed Air Cutting

Cost-Effective Solution One of the main advantages of compressed air cutting is its affordability. It provides a more economical solution. The equipment required for this technique is generally more affordable compared to other advanced cutting methods such as laser or water jet cutting. This makes it an attractive option for businesses that need an economical solution for precise cuts without high operational costs.

Precision and Clean Cuts Compressed air cutting offers high precision, especially when dealing with softer materials. It provides smooth edges and minimizes the risk of distortion, ensuring that your materials maintain their integrity. At Fine Cutting Solutions, we utilize advanced technology to ensure that each cut meets your exact specifications, providing you with exceptional results every time. Almost the speed of the nitrogen is achieved in air cutting

Minimal Material Waste The high precision of compressed air cutting minimizes material waste. Because the air nozzle is directed exactly where it’s needed, there’s little to no overcutting or wasted material. This efficiency not only reduces the environmental impact but also contributes to cost savings in your production process.

Versatility Compressed air cutting can be used for a variety of materials, including foam, rubber, plastic, and textiles. Whether you’re working with thick or thin materials, this cutting method offers versatility to suit your specific production needs. At Fine Cutting Solutions, we tailor our compressed air cutting services to handle a wide range of materials with ease.

No Heat-Affected Zones Unlike traditional methods such as laser or plasma cutting, compressed air cutting doesn’t generate heat. This is particularly beneficial when working with materials sensitive to high temperatures, such as certain plastics and foams, as it prevents any heat-affected zones (HAZ) that could compromise the material’s structure.

Quick Setup and Operation Compressed air cutting systems typically have a faster setup time compared to other cutting techniques, making them ideal for high-volume production. Once the system is in place, it’s ready to cut materials quickly and efficiently, helping businesses meet tight production deadlines without sacrificing quality.

Limitations of Compressed Air Cutting

1. Limited to Softer Materials While compressed air cutting is excellent for softer materials like rubber, foam, and plastics, it may not be suitable for tougher materials such as metals or thick composite materials. For harder materials, more robust cutting techniques like laser cutting, water jet cutting, or plasma cutting may be required.
2. Edge Quality May Vary Though compressed air cutting can produce clean cuts, the edge quality may not always meet the high standards of other cutting methods like laser cutting, especially when working with certain types of materials. For applications where edge finish is critical, this method may have limitations.
3. Air Supply Requirements Compressed air cutting relies heavily on a continuous, reliable air supply. If the air pressure or supply fluctuates, it can affect the precision and efficiency of the cutting process. Regular maintenance of the air compressor is necessary to maintain consistent results.
4. Not Suitable for Complex Shapes While compressed air cutting is precise, it may not be ideal for cutting intricate or highly complex shapes. Other techniques like laser cutting or water jet cutting may be better suited for highly detailed designs that require sharp corners or fine cuts.
5. Limited Cutting Depth The cutting depth of compressed air cutting can be limited, particularly when dealing with thicker materials. For deeper cuts, you may need to consider alternative cutting methods that can handle more substantial material thickness.
6. Noise Level Compressed air cutting can generate a significant amount of noise, especially when used in large-scale industrial applications. Proper hearing protection and noise reduction measures are essential to ensure a safe and comfortable working environment.
7. Some more Limitation: Limitations of compressed air cutting
   • In the case of Mild steel, there is a little dross but that is very low. The dross can be wiped. There is a black oxide layer formed on the cut surface.
   • In the case of Stainless steel, there is a yellowish / blackish colour on the cut surface.
   • During weld processing stainless steel after air cutting, the surface needs to be cleaned as the weld seam quality on the surface will not be proper.
   • The major disadvantage is that the quality of air cutting depends on the laser power. The higher the laser power the speed and quality of the cutting can be improved. Also the thickness limitation is also based on the laser power.
   • For certain application, the air cutting is undesired, as the oxidation on the surface is prolonged to react to its environment. Like aerospace, food processing, chemical tanks, vessels etc. where the surface is exposed to its environment. Because the cutting is done with air and oxidation is already on the surface, which continues to react and loses the original property of material (Corrosive resistance).
   • It requires proper maintenance of air generation setup on a periodic basis, else the optics in the cutting head may fail quickly.

Why Choose Fine Cutting Solutions?

At Fine Cutting Solutions, we understand that each project is unique and requires a tailored approach. Our team of experts specializes in providing precise and cost-effective cutting solutions, including compressed air cutting, for a variety of industries. With our advanced technology, experienced technicians, and commitment to quality, we ensure that your cutting needs are met efficiently and to the highest standards. The product range includes CNC plasma cutting machines and laser welding machines from hand guided machines right up to special machines for shipbuilding as well as machines and equipment for CNC laser cutting machine, cutting, brazing, soldering and heating. Spare parts, repairs, modernisation, maintenance and service as well as environmental technology round out the product portfolio.

Conclusion

Compressed air cutting offers a cost-effective, efficient, and precise solution for cutting softer materials like foam, rubber, and plastics. With benefits such as minimal material waste, no heat-affected zones, and quick setup times, it’s an attractive option for businesses looking for reliable and economical cutting methods. However, it does have limitations, particularly when it comes to cutting harder materials or achieving highly intricate shapes. It is one alternative way using assist gas in the laser cutting process by which you gain competitive speeds in production and reduce cycle time. Thereby reducing cost of production. However, the speed and quality of cutting depends on the laser power. If the application of air cutting prevails, then it is a good alternative with proper setup.

At Fine Cutting Solutions, we specialize in delivering high-quality compressed air cutting services tailored to your specific needs. Our team ensures precision and quality, helping you achieve optimal results for your projects. Whether you’re working with softer materials or looking for an affordable and fast cutting solution, you can trust us to provide the best results.