How Controlling Laser Power Output Improves Cut Quality
When it comes to laser cutting, power is one part of the equation. At Kern Laser Systems, we’ve found that less is often more, especially when you understand how to fine-tune the output of laser power for the material and application at hand. Whether you’re slicing through thick mild steel or kiss-cutting stickers, controlling the laser power output is one of the most effective ways to improve your overall cut quality and efficiency.
More Power ≠ Better Results
It’s a common misconception that maxing out the laser’s power will yield the best cut. While cutting at a higher wattage certainly has advantages, the real secret to high-quality laser cutting lies in precision, not brute force. Take our 500W laser, for example. If you’re cutting 3/16″ mild steel, you might think cranking up the power is the way to go. Instead, what you want to do is add enough power to just get through the material. Here are a couple of ways to find the right spot:
Lower the frequency to the range of 1000Hz to 2000Hz
– This gives you a lower pulse rate but a higher peak power per pulse. Find the right power and air assist.
This technique allows the laser to punch through the metal more effectively, while minimizing excess energy that could reflect off the cutting bed or distort the part.
Too much heat not only risks damaging your material and can lead to issues like:
– Increased slag and dross on metals
– More melt and distortion on softer materials such as rubbers and foams.
Precision at Every Level
One of the many impressive aspects about Kern’s laser systems is the flexibility. Using the same 500W laser source, you can go from heavy-duty metal cutting to delicate surface work, just by dialing down the power.
You can reduce your output to as low as 3–5% of total wattage, allowing you to:
– Kiss cut labels and stickers
– Etch fine lines on thin films and materials
– Perform light engravings without cutting through
This is where laser power control becomes a true art form.
How to Adjust Power for Better Cuts
There are several ways to control the laser’s output and tailor your cuts for the best possible result:
Change the Power Percentage
– Adjust the laser output from full power to just a few percent, depending on what you’re cutting or engraving.
Speed Up Your Cut
– Faster speeds combined with moderate power can help minimize burning or overcutting thin materials.
Adjust Frequency (Pulse Rate)
– Tuning the frequency can dramatically affect how energy is delivered—lower frequencies for deeper, peak-power cuts, higher frequencies for smoother finishes or engraving.
Each of these factors work together to help you optimize quality, reduce waste, and increase throughput, no matter the material.
Final Thoughts
At Kern Laser Systems, we equip you with more than just powerful machines, we give you precise control over every aspect of your cut. Power isn’t just about wattage, it’s about how you apply it.
So next time you’re setting up a job, don’t just max out the dial. Take a few moments to find your sweet spot and see just how far fine-tuned control can take you. Want to dive deeper into laser settings or get help dialing in a specific material? Contact our team or explore more tips on kernlasers.com
