Laser thermal forming of sheet metal parts using desktop laser systems

The bending of flat sheet metal materials using a laser process is not new to the metals industry. However, refining the process to the point where an angle bend can be predicted is significant when developing prototypes of small and large components. The methods and process developed to perform this task are presented, and key elements to maintain consistency and repeatability of the process are identified. A 50-Watt CO2 Desktop laser system provided the appropriate controls necessary to create the specific shapes. The forming tests were performed on CRES (302) with thickness varying from 0.26 mm to 0.64 mm. The variations of beam divergence, feed rate, laser power, and pulses per inch were evaluated, and the effects of these laser variables are presented. Material preparation techniques are also described since it was determined that the surface condition and the methods of edge preparation had significant effects on the overall results of forming. Compound radius bends were performed by calculating the...