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At ES3 we take pride in offering our customers high-quality laser cutting and metal fabrication services with a focus on a quick lead time and exceptional customer service. In order to provide the best possible service to our customers, it’s helpful to receive accurate and comprehensive CAD files that allow us to quote and supply parts quickly and efficiently. It is also useful to state the intended purpose of the finished part so that we can assess the necessary steps required to meet tolerances expected by the customer. Flat Laser Cutting DXF files are the most common for flat laser cutting. DXF stands for Drawing eXchange Format and these files typically contain vector data which provides an exact 2D representation of the part. These files are preferred by many customers due to their simplicity and they enable us to import directly into our laser software without any pre-processing required. Parts can be directly drawn in 2D and saved DXF files, however it’s usually a better idea to model your parts in a 3D environment then export DXF flat patterns for laser cutting. Folded Parts If you’re working with parts that have bends/folds then you should use appropriate bend radius and k-factor settings such as the ones we’ve calculated for our tooling . It’s also good practice to include the bend lines on your DXF flat patterns and also provide PDF drawings which show the bend angles, flange lengths, and any other important information. Tube Laser Cutting We generally use 3D models to program our tube lasers – the most common format being STEP . Other common formats include Parasolid and IGES . These formats make it easy for us to import the file into our software for quoting or production. We can also work off 2D drawings or sketches, however 3D models are particularly useful for complex parts where a 2D drawing may not provide enough information to fully understand the part’s design. What if I don’t do CAD? We understand that not everyone has access to CAD resources and our in-house CAD team is more than happy to assist if you need parts produced from sketches or photos. Contact Us If you have any questions or concerns about CAD file types or our fabrication process, please don’t hesitate to contact us. Our team can work with you to optimize your designs for laser cutting and sheet metal fabrication. We are committed to providing exceptional customer service and are always happy to help. Contact us today to learn more about our laser cutting and sheet metal fabrication services and how we can help with your next project.

In today's fast-paced manufacturing environment, the pressure to deliver high-quality products at a competitive price is greater than ever. To stay ahead, businesses are increasingly turning to advanced technologies that streamline production and enhance output. One such technology is tube laser cutting , a modern approach that outperforms traditional tube manufacturing methods in several key areas. This article explores the reasons why tube laser cutting is revolutionizing the manufacturing industry and how it can lead to significant cost savings, improved quality, better system integration, and a leaner production process. 1. Cost Efficiency: A Leaner Approach to Manufacturing One of the most compelling reasons to adopt tube laser cutting is the significant cost savings it offers. Traditional tube manufacturing methods often require multiple steps, including cutting, drilling, and milling, each demanding separate tooling and setup time. This not only increases the overall production cost but also requires additional labour and management. Tube laser cutting, on the other hand, consolidates these processes into a single operation. By eliminating the need for multiple machines and reducing setup times, manufacturers can achieve a leaner production line. This streamlined approach not only reduces labour costs but also minimizes the amount of material waste, further driving down expenses. 2. Enhanced Quality and Precision Quality is non-negotiable in manufacturing, and tube laser cutting excels in this regard. Traditional methods, while effective, can introduce variations in cut quality, especially when dealing with complex geometries or tight tolerances. These inconsistencies can lead to defects, requiring rework or, in the worst-case scenario, scrapping of parts. Tube laser cutting offers unparalleled precision, producing clean cuts with minimal burrs and reducing the need for secondary finishing operations. This level of accuracy is particularly beneficial for industries where tight tolerances are critical, such as aerospace, automotive, and medical device manufacturing. The result is a higher-quality product that meets stringent standards, reducing the likelihood of costly errors and rework. 3. Improved System Integration and Automation In an era where automation is becoming increasingly vital, tube laser cutting stands out as a technology that seamlessly integrates with modern manufacturing systems. Many tube laser cutting machines are equipped with advanced software that allows for easy integration with CAD/CAM systems, facilitating automated production. This integration reduces the need for manual intervention, allowing for quicker transitions between different projects or batch runs. The ability to automate the cutting process also means that production can continue with minimal supervision, reducing the burden on production management and freeing up resources for other critical tasks. 4. Reduced Tooling Costs Tooling costs can represent a significant portion of a manufacturing budget, particularly in traditional tube processing methods that require different tools for different operations. Over time, these costs can add up, especially when considering the wear and tear on tools, the need for regular maintenance, and the potential for downtime during tool changes. Tube laser cutting drastically reduces or even eliminates the need for physical tooling. Because the laser can cut a wide variety of shapes and sizes directly from digital files, there’s no need to invest in specialized tools for each project. This not only lowers the initial investment in tooling but also reduces ongoing maintenance costs and the risk of production delays due to tool wear. 5. Lean Manufacturing: Streamlining the Production Process Lean manufacturing principles emphasize the elimination of waste, continuous improvement, and maximizing value to the customer. Tube laser cutting aligns perfectly with these principles by reducing material waste, minimizing production steps, and enabling faster turnaround times. The precision of laser cutting ensures that material usage is optimized, with less scrap generated compared to traditional methods. The ability to quickly switch between different cutting profiles and materials also supports just-in-time manufacturing, reducing the need for large inventories and further cutting costs. The adoption of tube laser cutting in place of traditional tube manufacturing methods is a strategic move that offers numerous advantages. By reducing production costs, enhancing product quality, and supporting lean manufacturing principles, tube laser cutting can help manufacturers stay competitive in an increasingly demanding market. As the manufacturing landscape continues to evolve, those who embrace this technology will be well-positioned to deliver superior products while maximizing their operational efficiency. ES3 services tube laser cutting needs all across New Zealand, get in contact so we can provide solutions for you also.

Many of us have heard of tube laser cutting but few truly understand the extent of the revolutionary solutions that can be achieved with creative tube manufacturing techniques. Continue on for a simple visual reference on the what is made possible with tube laser cutting... Increase the quality, accuracy and consistency of your components Improve ‘Lean Manufacturing’ by not holding semi -manufactured parts in stock, less storage and less handling Reduce the need for making assembly and welding jigs, no cost for building or set up time Create the ability to flat pack saving on shipping and storage costs Eliminate or minimise set up and tooling costs Reduce management and focus your time where it counts Stats show using Tube Lasers can reduce time on each part by 49% and cost per part by 31% compared to conventional methods. The Possibilities with both Bend and Connection Innovation ES3 Success Stories in Tube Laser Cutting “As manufacturers of Agricultural Machinery, we have traditionally used very conventional methods to process our hollow components: sawing, plasma-cutting, drilling, etc. and considered these to be cost-effective. But we are changing. Having now experienced the accuracy, uniformity, and versatility of having components Tube-Lasered by ES3, we are looking for more opportunities to save time and money using this fantastic process. The excellent design support, the willingness to do small batches and fast service provided by ES3, has proved to be a winning formula for us. Thank you ES3!” - Palmerston North Customer "Back when our business was in its infancy we were struggling to manufacture our lifts fast enough and efficiently enough to meet the demands of the market. A chance discussion with a friend led to an introduction to ES3 who showed me some images of samples of what they could do with their amazing 3D laser machines. Instantly I knew this was going to be a game changer for us, the answer to all of our manufacturing problems! So we immediately redesigned our entire lift structure so it could be made by components cut by ES3 and we were off. Many years have passed since then and thanks to ES3 and their amazing service and co-operation with our requirements, our company has grown to lead the market in making the highest quality residential elevators available in NZ. We couldn't have done it without ES3 and they continue to be a key partner in our evolving business." - Tauranga Customer Learn More Check out our other post on the potential of our Nukon NK-T160 Watch the Trumpf Innovative Tube Constructions Video Follow USA based Precision Tube Laser on Instagram Download our Tube Manufacturing Revolution flyer to show you team Get in touch with ES3 to start using tube laser cutting services or find out how you could more effectively use them.

In our latest blog article, we run through the key attributes that make the Nukon NK-T160 a fantastic addition to the ES3 team. Our Nukon 4kW Fiber Tube Laser is still referred to as ‘the new tube laser’ here at ES3, but it’s been well over a year since it was commissioned. Time flies when you’re having fun! We’re pleased to say that the Nukon has earned its place as a productive member of our laser cutting line-up. One of the most significant advantages this has given our clients is that the NK-T160 has allowed us to process larger and thicker materials, as well as up to 45° bevel cutting. High-Precision Cutting Thanks to its advanced laser-cutting technology, the NK-T160 is exceptionally accurate. This precision is crucial for our many clients’ intricate manufacturing requirements, ensuring flawless (and precise) results every time. High-Efficiency With rapid cutting speeds and efficient workflow management, the NK-T160 optimises production timelines without compromising on quality. ES3 can now meet deadlines with ease while maintaining the highest standards of quality. Innovation and Future Growth In today’s dynamic business landscape, staying competitive makes it crucial to have a forward-thinking approach. The adoption of the Nukon NK-T160 positions ES3 as an industry leader, capable of delivering precision-engineered solutions and exceeding our customer expectations. As we continue to unlock the full potential of the NK-T160, the outlook for future growth and innovation remains exceptionally promising. Looking Ahead The Nukon NK-T160 represents more than just a new machine acquisition for ES3 – it helps demonstrate our commitment to excellence, innovation, and operational efficiency. With this strategic investment, we are well-positioned to navigate the evolving market demands and set new benchmarks in manufacturing excellence. The following table details the machine capability specifications. Max. Tube / Pipe Diameter 226 mm Max. Rectangular Hollow Section Size 200 x 100 mm Max. Square Hollow Section Size 160 mm Max. Wall Thickness – Mild Steel 10 mm Max. Wall Thickness – Stainless Steel 8 mm Max. Wall Thickness – Aluminium 8 mm Max. Raw Material Length 8 m Max. Finished Part Length 6.5 m Max. Raw Material Weight 35 kg/m Our two-tube lasers offer substantial capacity to help meet our clients’ requirements. Don’t hesitate to contact the ES3 team to discuss your specific requirements.

The latest addition to our arsenal of press brake tooling is something a little different – a polyurethane forming die. It consists of a steel channel with a specially shaped piece of polyurethane inside. Watch the video below to see it in action bending 5mm steel with a 100mm radius punch. There are a wide range of polyurethanes for different applications. The type used for press tooling like this would be an elastomeric variety which means it has elastic properties; this is why it returns to its original shape after pressing. You might notice in the video above that the punch is retracted relatively slowly – we intentionally configured the press to decompress slowly over a certain distance rather than just removing the pressure immediately. This is to avoid the ram being forcefully pushed back up when the polyurethane returns to it’s original shape. You might be wondering why we’d use such a tool instead of a traditional steel die. The main reason is the flexibility it gives us when performing larger radius bends. We can use a single die to form a large range of radii by only changing the punch. The radius shown in the video above is 100mm and there’s plenty of room to go larger. Another benefit of the plastic die is the mark-free bends it produces. The relatively soft material and large contact area with the part means that there are no visible die marks on the outside of the bend. This is particularly helpful with aluminium or stainless parts where the aesthetics are important. If you have any questions about our folding capabilities or would like us to quote on your next project, please don’t hesitate to get in touch.

Laser cutting has significant advantages over alternative metal cutting methods, providing the precision and power that helps modern metal fabricators produce results on an unprecedented scale! It is one of the most basic and widely used processes in metal fabrication today, and as the technology is constantly developing it will only continue to offer more benefits as time moves on. There are a wide variety of materials which can be laser cut, with numerous benefits over alternative cutting methods. Below are some of these advantages: The process is fast and reliable which improves turnaround times. Relatively energy efficient. Non-ferrous metals can be cut with ease. Suitable for a range of thicknesses (from 0.55mm to 30mm). Complex shapes can be cut with precise detail. Cut edge quality Traditionally, plasma or water cutting were seen as more cost effective than laser cutting, but they do not provide anything like the quality of a laser cut edge. With improvements in technology, efficiency, and power, these traditional cutting methods have become far less valuable compared to laser cutting. Laser cutting has less heat distortion, is cleaner and quicker than traditional methods meaning there is less work to do after the parts have been cut. Faster cutting and turnaround times A laser cutting machine typically does not require complex tooling or setups. The operator can switch between different material types and/or thicknesses simply by selecting the appropriate settings on the machine and changing the nozzle to suit. This low initial setup time can make the overall process of cutting the parts a lot quicker than other methods. There is also less clean up required on the parts after cutting. If the machine is set up correctly and cutting nicely, parts can often be taken directly to the next process without the need for deburring. ES3 Laser Cutting Services There are clear advantages in laser cutting, enabling cost-effective solutions with precise results. With ES3’s world class machinery and experience, the possibilities for metal fabrication are endless. We are continuing to invest in our people, in machinery and technology to provide you with the engineering solutions you need. Our team can support you with small batches or large production runs, so if you are interested in using laser cutting for your next project, please get in touch with our team at sales@es3.co.nz to see how we can help bring your designs to life.

Robot welding and manual welding both have their pros and cons, and fabricators must keep these in mind when making decisions on which method to use. Robot welding is better suited to large production runs of repeatedly manufactured items, whereas manual welding is ideal for smaller runs, custom jobs, or smaller items requiring special care and attention to detail (such as TIG welded stainless). Robot Welding Pros: Consistency. A correctly programmed robot is capable of producing very tidy and high quality welds with little variance in bead size or weld penetration. Productivity. Robot welding is usually significantly faster than manual welding, allowing more product to be manufactured in the same time period. Predictability. Once a job is programmed it will always take the same amount of time to run, unlike manual welding where there can be large variances depending on the experience of the welder and/or familiarity with the job. Cons: Jigging requirements. Any variances in the locations of the components or gaps between components will affect welding quality, or possibly cause a collision. This means that more extensive jigs are often required. Setup time. The programming and jigging requirements add a lot of time to the process before the first part can be completed, which makes it unsuitable for lower quantities. Manual Welding Pros: Flexibility. Design changes or custom requirements are easy to accommodate. Setup time. Welding can commence a lot quicker at the start of the job, especially if the parts are self-jigging which reduces the need for building complex jigs. This is especially beneficial for prototypes. Awareness. Having an experienced fabricator on the job increases the chance that any mistakes or issues from previous manufacturing processes will be noticed and dealt with before welding takes place. Cons: Consistency. Welding can vary depending on the fabricator on the job. Safety. Manual welding comes with a higher chance of injury. Speed. A robot can be a lot faster, particularly on jobs with a lot of welding required. When ES3 consider a job for our robot welder we take into account the above points, along with details such as the minimum order quantity, order frequency, and annual usage. If you would like to learn more about our fabrication capabilities, don’t hesitate to contact the team at ES3.

A common question in the tube laser industry is what corner radius should be used to model SHS/RHS parts for Tube Laser Cutting . The short answer we usually give is 1.5x wall thickness (WT), but there’s more to the story. A lot of the CAD models we receive have been drawn with the manufacturers specification which can be up to 2.5x WT for the external radius. This may be technically correct, but in our experience with tube laser cutting it’s better to program the cutting path based on 1.5x WT (we usually adjust the model at the programming stage if required). The difference lies in the fact that the corner radius doesn’t always meet the sides at a tangent as illustrated in the image. If we programmed the tube laser based on a 12mm corner radius it would start rotating the material too early, resulting in a potential nozzle collision and decrease in cut quality. There can be small differences in the exact profile depending on the steel manufacturer, but we’ve found that using a corner radius of 1.5x WT gives consistent results and improves cut quality.

As a sheet metal fabricator, we understand the importance of smart material utilisation. It plays a huge part in offering our clients the most competitive solution. While we strive to optimise this as much as possible, we also need to be aware of how grain direction can influence the quality and consistency in the folding process. Where does grain direction come from? Grain direction is a term used to describe the rolling direction of metal after being manufactured into sheet, plate, or coil. This manufacturing method is where hot metal is compressed through rollers and forced into shape, elongating the crystals in the process. Before processing, the crystals vary in both size and orientation, but then form in the direction of rolling, becoming the grains we see running the length of the sheet. How does this affect folding? Any experienced press operator will have come across it before – you’ve just got the press dialed in to bend a part accurately, but a few parts later the angles are coming out inconsistent, sometimes even a few degrees out! This is usually a sign of the parts having been laser cut from a sheet with random grain directions. The grain direction affects the spring-back of the material and hence the resulting angles after pressing. In some situations the material can even crack if the bend line is parallel to the grain (this is particularly problematic with some grades of aluminium). When folding, steel is strongest when bent against the grain. Bending sheet metal with the grain (longitudinally) increases the possibility of the grains separating at the grain boundaries. This limits how tight of an inside bent radius you can achieve without cracking the outside of the bend [see above image]. Bending like this (with the grain) can be less consistent, however less pressure is required to make a bend. In summary, variations and cracking when bending longitudinally can be influenced by both the material and the application. Therefore, when it comes to grain direction in parts being bent, the most important element is consistency in direction. Grain Direction Is Important Optimising material utilisation in nest layouts is vital when parts are remaining flat. If batches of parts are being bent with some against, some with and others diagonal to the grain direction of the steel, each angle and dimension may vary across the entire batch. To amend this, we must cut parts in a uniform way, with grain direction marked on the parts. As a result, the quality and consistency of bending will be increased, therefore yielding better results and more accurate parts.