Laser Cutting
Precision Laser Cutting Services for Metal Prototypes
Laser cutting uses a focused, high-intensity beam of light to melt and vaporize material along a programmed cut path. For thin-gauge metal prototypes requiring tight dimensional tolerances and well-defined edge geometry, laser cutting offers a combination of speed, accuracy, and repeatability that makes it the preferred method at Brunk for a broad range of prototype applications. Brunk uses Trumpf laser systems for both cutting and welding operations, and the same equipment that supports prototype cutting is also used in production, which means prototype parts are processed on production-grade equipment rather than on a separate prototyping-only platform.
Process Characteristics and Capabilities
Laser cutting at Brunk is performed on Trumpf fiber and CO2 systems capable of processing a range of metals from thin foil stock up to approximately 0.25 inches thick, depending on material type. Fiber lasers are better suited to reflective metals including stainless steel, aluminum, and copper-based alloys because the shorter wavelength is more efficiently absorbed by these materials. CO2 systems are used for applications where beam characteristics favor the longer wavelength. Cut tolerances achievable on well-fixtured flat stock are typically within ±0.001 to ±0.003 inches, depending on material and feature geometry, which is sufficient to produce prototype parts that can be used directly in assembly and functional testing.
The heat-affected zone produced by laser cutting is narrow and in most cases does not affect part performance for prototype evaluation purposes. For materials where any heat input is unacceptable, waterjet cutting is used instead. Brunk’s applications engineers assess this on a program-by-program basis and will recommend the appropriate method based on material specification and downstream use of the prototype part.
Applications in Precision Prototyping
Laser cutting at Brunk is used most frequently to produce flat-pattern blanks and near-net-shape profiles that will be evaluated for dimensional accuracy and assembly fit before forming tooling is built. For components with complex 2D profiles, internal cutouts, or fine features in thin-gauge material, laser cutting can produce prototype parts that closely represent the geometry of a progressively stamped blank without requiring a dedicated blanking die. This is particularly useful early in a program when the design is still being iterated and tooling investment is not yet warranted.
Laser cutting is also used to produce prototype parts for functional testing in applications where the flat or lightly formed geometry of the cut part is sufficient for the test objective. For medical device components, laser-cut prototypes in the correct material and heat treatment condition can support early biocompatibility and material characterization work while stamp tooling is being designed.
Request Laser Cut Prototype Parts
Submit your drawings or CAD files for an assessment of laser cut prototyping options for your program.
Frequently Asked Questions
What tolerances are achievable?
Depending on material and thickness, ±0.0005 in to ±0.001 in is common for medical components, with tighter results on thin sections and with ultrafast lasers. Our TRUMPF-powered medical laser cutter cells maintain these tolerances on flat parts and during laser tube cutting for hypotubes.
How does laser cutting compare to EDM or stamping?
Medical laser cutting avoids hard tooling and often reduces lead time and total cost for intricate features. EDM may be preferred for very thick parts or extremely precise internal features, while stamping excels for high-volume, simple geometries. Many programs combine processes to suit feature requirements; Brunk helps select the right mix for medical device manufacturing.
Does laser cutting affect biocompatibility?
With optimized parameters, inert assist gases, and validated cleaning and passivation, laser-cut parts can meet biocompatibility standards. Ultrafast lasers further minimize thermal effects on sensitive materials, supporting demanding precision medical devices.
Is laser cutting economical for small batches and prototypes?
Yes. Digital toolpaths and rapid changeovers make medical laser cutting ideal for prototypes and low-volume builds, enabling quick iterations without new tooling. This agility is central to Brunk’s medical manufacturing and development services.
