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In the metal shaping industry, a part coming out of a deep drawing press is never a “finished product.” Irregular edges and “earing” caused by the flow of material constitute the most critical bottleneck of the production line.
Many manufacturers turn to traditional methods or high-investment 5-Axis Laser Cutting machines to fix these edges (trimming). However, when a rational engineering analysis is conducted, it becomes clear that in mass production scenarios, the “thermal cutting” principle of laser cutting is inferior to mechanical trimming and forming technologies like the Emin Mekatronik EMK Series, both in terms of cycle time and unit cost.
In this article, we will transparently compare these two technologies—which directly impact your production line efficiency—across the axes of speed, cost, and quality.
- Speed and Cycle Time Analysis
Laser cutting technology is flexible, but it has a physical limitation: the cutting head (nozzle) must travel around the entire perimeter of the part. In cylindrical, square, or asymmetric deep-drawn parts, this time is measured in minutes.
The EMK-600 and higher series developed by Emin Mekatronik, powered by the Siemens Motion Control System, process the part at high speed, reducing this time to seconds.
Laser Cutting: Edge trimming of an average boiler tank or a large-diameter pot: 90 – 120 Seconds
EMK Horizontal Trimming: Trimming + beading of the same part: 8 – 15 Seconds
Engineering Note: EMK series machines do not just trim; they perform internal/external beading, curling, and ironing operations within the same cycle time. A laser cannot perform these tasks; they would require a second operation, a second machine, and extra labor.
- Precision and Cut-Edge Quality
Laser cutting is a thermal process. Especially in sheet metal with a thickness of 2mm and above, attempting high-speed cutting results in “burrs,” “burn marks,” and a Heat Affected Zone (HAZ) on the edge. This requires an extra cleaning (sanding/grinding) process before painting, enameling, or welding.
The EMK series (e.g., EMK-800 or EMK-HD800), with its rigid construction and specially designed blade systems, operates with “machining” precision.
Result: Burr-free, cold-formed, and smooth surface.
Capacity: You won’t experience the focusing problems of a laser on parts from 0.5mm up to 4mm (up to 6mm on the R600 model).
- Operational Expenses (OPEX) and Maintenance
When making an investment decision, not just the sticker price but the resources consumed over the machine’s lifespan must be calculated. Here is the brutal reality:
Expense Item 5-Axis Laser Cutting EMK Horizontal Trimming
Consumables Lens, Nozzle, Cutting Gas (Nitrogen/Oxygen) – High Cost Blade sharpening (Long-lasting and cheap) – Very Low Cost
Energy Consumption Resonator, Chiller, and Extraction System – High kW/h Servo Motor Technology – Low kW/h
Maintenance Optical path cleaning, bellows replacement, precision calibration. Standard periodic maintenance with Automatic Lubrication System.
Operator Requires expensive CAM software and highly skilled experts. Operators adapt easily with the Emin Mekatronik custom interface.
- Multi-Functionality: Don’t Just Cut, Form
A laser machine only cuts. However, if you are producing a boiler, a traffic sign, or a filter box, you usually need a form (bead, bend, etc.) after trimming. Our EMK and R Series machines are modular:
Trimming: Removes the excess material.
Beading: Adds a bead for strength or assembly.
Curling: Bends sharp edges inward or outward.
Flanging: Widens the part opening.
You perform all of these in a single setup. You don’t waste time removing the part and mounting it on another machine.
Conclusion: Which Technology is Right for You?
To be honest, there is no single right answer for every job.
Choose Laser if: You produce only 50-100 units per month, your part form changes every day, and you are working on prototypes.
Choose Emin Mekatronik EMK Series if: You are engaged in mass and standardized production such as Water Heaters, Boilers, Fuel Tanks, Cookware, Automotive Parts, or Traffic Signs.
For example, using a laser in the production of Boiler Outer Body Sheets means burning your factory’s profitability. EMK production lines take this process from the coil and solve it on a single, hands-free line, including cut-to-length, punching, and forming.
The “future” in industry is not just robots or lasers; it is choosing the right machine for the right job. As Emin Mekatronik, with our technology reaching the world from Kayseri, we offer our customers not the “most expensive,” but the “most efficient.”
