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 [M. Pridham and G. Thomson, Mater. World 2, 574 (1994)]. The methods and process developed to perform this task along with applications of the laser forming process are presented, and key elements to maintain consistency and process repeatability are identified. A 50 W CO2 Desktop laser system provided the controls necessary to create specific shapes from CRES (302) with thickness varying from 0.26 to 0.64 mm. Effects of variations of beam divergence, feed rate, laser power, and pulses per inch, are presented. Material surface condition and material preparation techniques have significant effects on the overall outcome of forming and are therefore discussed. Compound radius bends were performed by calculating the effects of simple bends in conjunction with multiple passes. Experimental data were compiled and a section on the analysis of these data is also presented.