TRUMPF reduces hot forming costs with laser cutting technology

Automotive manufacturing, particularly hot forming of safety-critical body components, requires high-precision cutting processes with consistent quality and cost efficiency. In this context, TRUMPF has introduced a laser cutting solution that reduces component costs while improving process stability in hot-formed part production.

The solution combines a newly developed cutting nozzle, a new generation of fibre lasers and beam shaping technology to optimize laser cutting performance. It was presented at the INTECH exhibition in Ditzingen.

Increased process stability and reduced downtime
A central component of the solution is a redesigned cutting nozzle that allows a greater distance between the nozzle and the sheet metal during processing. This reduces the likelihood of collisions, which have traditionally been a common cause of machine downtime and inconsistent cut quality.

By minimizing contact risks, the system improves operational reliability, even under variable production conditions or less optimized programming. Extended nozzle service life—exceeding three months in testing—also reduces maintenance interventions compared to previous solutions, where replacement intervals were significantly shorter.

Lower cutting gas costs through compressed air
The solution enables the use of compressed air as a cutting gas instead of nitrogen, which can reduce gas-related costs by up to 75%. While nitrogen has typically been preferred for its process stability, compressed air offers a lower-cost alternative but has historically been less reliable in continuous industrial use.

Through the combination of the X-Blast 2.0 nozzle and BrightLine Speed beam shaping technology, TRUMPF enables stable cutting performance with compressed air, including in high-productivity, continuous operation environments.

Energy-efficient cutting with beam shaping and fibre lasers
BrightLine Speed technology improves cutting efficiency by shaping the laser beam to achieve higher cutting speeds at lower power levels. For example, equivalent or higher performance can be achieved with lower laser power compared to conventional systems.

The integration of a new generation of fibre lasers further enhances energy efficiency by reducing power consumption at the beam source. Lower required laser power also decreases the total energy consumption per component, contributing to overall cost reduction.

By combining optimized nozzle design, beam shaping and energy-efficient laser sources, the solution addresses key cost drivers in hot forming processes, including gas consumption, energy use and machine downtime, supporting more efficient production of automotive body components.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

www.trumpf.com