what are you using for air assist [Archive]

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Darryl Messer

I am still trying to do all my homework before my laser purchase, i talked with the universal rep today and he said there air assist is an additional .$$$
I am sure i will be needing this but the budget sure didnt figure in this one.

What is so special about there air assist?
What are you Using for yours?

I have a large 80 gal compressor in the shop but its sure not dry air, and a water filter system doesnt seem to work that well on it.

Thanks Darryl

Joe Pelonio

Is that for the pump, or the plumbing in the laser unit? Air assist is critical for most if not all cutting. Without it you will get charring and flames, and that's dangerous and will ruin many items.

Mine came with air assist installed, but they wanted $300 for a pump. Since I had several compressors and air brush pumps I didn't get it.

Currently for most work I use an airbrush compressor (25 PSI) that cost $79, with an air filter on it. If I need more pressure I have a small, fairly quiet portable compressor that I keep nearby mainly for small spraypaint jobs and cleaning the laser with the blowgun.

Your big compressor is overkill and will drive you nuts with the vibration and noise, especially when you get a big cutting job and run all day.

Darryl Messer

Joe, i dont really know what is included with that price.

my large compressor is is very much a pain to listen to all day, it doesnt come on that much but its in the shop with you when it does, so i had originally planned on moving it out because i dont use it much anymore.

Joe Pelonio

On my Epilog, as long as the air is connected, when not calling for assist the air runs continuously through a solenoid operated bypass. That means that air is running out under the machine. When your settings call for assist it's a full flow, about 1/8", so your compressor might come on frequently even with the 80 gallon tank.

Darryl Messer

I wonder why they designed it with a bypass type valve instead of a shutoff/on type of electrical solonoid, does the air noise bother you listening to it all day?
I dont know what i am going to use at this point, i may just go ahead and make my purchase and deal with this when i buy my exhaust and plumb it all in at the same time.
Sure looks like this could be simpler than the Manufacturers of these machines are making it.

Mike Mackenzie

Darryl,

The ULS air assist is more than just supplying air at the Len's it has air curtains around every optic from the beam window to the Len's. It is basically a complete optics protection system.

It is controlled by color and also has a gas connection as well you can tell the system to supply high air pressure, low air pressure, gas, or combined.

You will need to have in-line water trap, coalescing filter, regulator, and on/off ball valve.

We use our Home depot compressor and have never had any moisture get through the lines and onto the Len's.

The air assist is conical so a cone is placed on the bottom of the X axis carriage and then air is forced through the cone directly at the laser cut. This helps a lot when cutting because you are forcing the material through with the air as it is cutting.

You will not use air for everything you do so the cone comes off very easy and if you run your air it will still have a curtain around all of your other optics at all times. This dramatically reduces debris from getting onto the optics.

It absolutely does not mean that you do not have to maintain your optics it just reduces the regularity at which you have to clean them

Bill Cunningham

I have my air hose on a quick disconnect. If not for that, the compressor would run all day.. When the air is on, I find that even though my compressor is small, (4cfm nailgun type) it's on the second floor of my shop, and starts about every 3 or 4 minutes.. The air your using is 'regulated' to a really low pressure (25-40 psig) , and the pressure drop on a 80 gallon tank will take quite a while. If you normally start about 90, and shut off about 110 you will consume roughly about 18 cf before your compressor kicks in again..With a 1/8" flow, regulated to 25-40 psi, you won't be bothered all that often.. A inline desiccant dryer just ahead of the regulator should dry your air to a acceptable level

Peck Sidara

Darryl,

The Epilog Mini/Helix & Legend EXT comes standard with pre-plumbed air-assist. All you'll need to do is supply the recommended air pressure. An optional pump is available at a fraction of your quoted cost. Another option is to purchase your own low cost air-compressor pump used not for your air tools but rather something like air brushing. Just regulate it to 30-32 PSI, a bit more is also okay.

Air assist is primarily used for vector cutting, keeps the flames down and provides a cleaner cut. Most will swear by it and consider it a must while a few others (depending on their application) don't rely on it as much.

Epilog's air-assist is controlled via a solenoid, you can turn it on for raster/vector or both as well as color mapping. Additionally if you'd like to run your own compressor w/o the nuisance (sp?) of your compressor constantly being on, you can reverse the solenoid so there's no air-leak.

I saw your posting regarding current sales and a few things popped out:

Air-assist blows air over the materials when vector cutting or raster engraving
Vacuum suction utilizes the exhaust (exiting air) to keep your materials nice and flat onto the table and draws smoke down into the table and out back.
Nows a good time to buy, you'll find many manufacturers offering specials w/ ARA coming up next week.
Our lasers(120W exception) come standard w/ a 2 year warranty and a replacement, if needed, can be had for as little as $995.Will you be attending the ARA show in Vegas next week? Good opportunity to compare various models and to meet the manufacturer.

Epilog won't be the cheapest and for good reason. If price is the deciding factor in your decision, talk to your local rep or feel free to send me a PM. We'll do our very best to earn your business.

HTH,

Benedict Roussos

I have a universal laser with air assist and I'm 100% satisfied with my choice. You 'll extend the life of your laser optics at least 2 years. And I never got fire with air assist. You can search for the most economic way to buy a compressor but if you finaly choose universal then ask for air system preinstalation

Scott Shepherd

You can't use the inexpensive airbrush compressor to run the ULS system. Most of those air brush compressors provide .9cfm in the 20-30PSI. That's not enough flow to provide the air screen for the optics as well as the air assist for the vector cutting, if my understanding is correct.

You can certainly use your existing compressor, you just need dry, clean air. One drop of water in the system and onto a mirror while it's cutting and you'll probably fracture the mirror. You can buy inexpensive driers and filters for your existing compressor.

Robert Ray

I have had great success using a continuous duty rated Thomas Diaphram Pump (http://www.rtpumps.com/thomas/central/products/resource.nsf/imgref/Download_107CAB-CEF_Diaphragm___2-07.pdf/$FILE/107CAB-CEF_Diaphragm___2-07.pdf). They don't get hot, and provide enough air for the job, and you can often find them new surplus around the $50 price instead of the $200 new price.
I use an air filter with water trap (http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=), and leave the bottom petcock cracked open just a bit, then the water always blows out instead of making it's way to the nozzle.

-Robert

Scott Shepherd

Robert, are you using that on a Universal laser? In the link you provided, the CFM was very low, way below the requirements to run the ULS system and even below the normal Airbrush compressor.

It's showing .14 CFM at 30PSI. The ULS needs 2.5CFM or better at 40PSI if I recall correctly (or something close to that).

Mike Shauer

Your shop compressor will work just fine. The water trap and filters are cheap. Mine is outside in a lean to and plumbed around the shop. I have a regulator and ball valve next to the laser and turn it on when I need it.

My laser came with the compressor from ULS. It is a well made thing with cooling fins and water traps. When it was about 1 1/2 years old the motor quit and I put it on the shelf connected the big one and never looked back. Its a $250.00 bill to fix which I will do for resale when I upgrade my laser, It's a selling feature for my old one that I now no I didn't need but i sure look nice when I bought it.

It's like most thing I had no idea what I was buying three years ago. Today it would be the most power first then the largest table. If you balance those two out the rest can be fixed later.

ULS will treat you right, the service staff knows their stuff, the replacement laser tubes are the best price in the industry and its a well made machine.

Cheers, Mike

Sandra Force

I will agree that your shop compressor should do the trick. I like the idea of leaving the valve on the bottom of the water trap open slightly. I think that with a good filter system and air dryer things should work nicely. Just remember even with those in place if you are not running the compessor for 3 or more days to bleed it off at the quick release nearest the laser to remove any condensation that has developed while it was off. I have found that my system developes some during high humidity when I have it off for that long.

Kevin Huffman

With our air compressor, (GCC or LTT Lasers) we have 3 things that must be.

1. Waterless
2. Oil less
3. 18-20 psi.

Everything past that is icing on the cake.

Robert Ray

Robert, are you using that on a Universal laser? In the link you provided, the CFM was very low, way below the requirements to run the ULS system and even below the normal Airbrush compressor.

It's showing .14 CFM at 30PSI. The ULS needs 2.5CFM or better at 40PSI if I recall correctly (or something close to that).

I'm using mine on the Laser Pro Venus machines. I run at 10 PSI, which is almost all the way opened. The Laser Pro has a nozzle cavity under the lens, so the air flow blows straight through the cut. The .5 CFM flow seems pretty good, and blows small cutouts and dust away fine. It would not be enough for a blow back, but for air assist it's good.

kapa supply professional and honest service.

Scott Shepherd

Gotcha Robert, that won't work with the air screens around the various optics as well as vector cutting on the ULS. Not enough CFM or PSI, and it will alarm out with too low of air pressure and the machine will sit until the air pressure is high enough.

Richard Rumancik

I wonder why they designed it with a bypass type valve instead of a shutoff/on type of electrical solonoid, does the air noise bother you listening to it all day?

They designed it with a bypass because a small diaphram type compressor can't be blocked on the output. If you do this it will keep trying to pump into a closed hose and probably damage itself. To prevent damage you would need an electrical shut-off on the compressor, activated by pressure in the hose (or a solenoid closure). All of this adds complexity so they did it the simple way - continuous running with bleed-off.

I have seen some airbrush compressors with some kind of control where they would start "on-demand" but I don't know what kind of components they use to implement this. This would avoid continuous running.

I converted an obsolete oxygen concentrator to use as a compressor. It is quiet (as it normally is used in a residence) and seems to work well. The biggest problem was finding a suitable switch/unloader valve. You need an unloader valve to relieve the pressure in the compressor output hose. Otherwise, the compressor can't re-start and stalls. On a shop compressor, when it turns off, you hear a "pssssst" after it stops. That is the unloader valve emptying the supply line, so that it can re-start freely on the next cycle.

Jim Dornon

I am adding air assist to my Rabbit . Thought you all might like this pump.
http://www.aquariumguys.com/superluftpump.html:D

Bill Cunningham

If your running a piston type compressor in your shop all day long, your far better off to unload the intake, usually done by a air relief valve activating a piston that either holds the 1st stage intake valve open, or clamps off the compressor intake itself, thereby allowing the compressor to free wheel between cycles. This is far easier on the compressor, the electric motor, the electric bill, and your ears. When the compressor just cycles, it's fairly quiet.. Then, when the pressure drops, a spring backs the unloading piston off, and the air cycle begins again.

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If you laser-cut metal for a living, you are no doubt familiar with assist gas. You may know that nitrogen and oxygen are the most popular of these gases, and you may have even heard that air is a cost-effective alternative to those gases. But how do you know if air-assist is right for you in your laser cutting operation? Here are three things that you should know about air-assisted cutting.

1. How Does Air-assisted Laser Cutting Work?

Neither fiber nor CO2 lasers rely strictly on a light beam for cutting metal. Rather, the process includes the injection of an assist gas at the nozzle to supplement the process. This confluence initiates a process known as an exothermic reaction&#;a chemical reaction that releases energy by light or heat. The introduction of nitrogen, oxygen, or air helps transfer heat more effectively than the beam alone.

Initially oxygen was the most popular gas for the laser cutting process. Later it was discovered that nitrogen produced a cooler cut, resulting in cleaner edges, perfect for industries where aesthetics and edge quality were critical. While nitrogen remains the most widely used laser cutting gas, air is proving to be an effective and cost-saving alternative for a growing number of fabricators.

This is not to suggest that air-assisted cutting is a radical departure from nitrogen or oxygen. Air is, after all, approximately 80 percent nitrogen, with the rest consisting primarily of oxygen. The goal with air-assist cutting is to use this high concentration of nitrogen while at the same time leveraging the added benefits of substituting a slightly more diluted gas.

2. What Are the Advantages of Air-assist Laser Cutting?

While relatively new to some, air-assist cutting has been around for nearly 20 years. Machine tool manufacturers began researching and developing the process as early as .

Since that time the use of air as an assist gas has continued its steady growth in popularity among both fiber and CO2 laser users alike. Mode quality was a major limitation when compressed air was first introduced for CO2 lasers, but that has improved significantly. Today air-assist is an efficient and popular method for cutting a variety of materials, even stainless steel and aluminum.

Air carries with it a substantial return on investment for those employing fiber lasers or those cutting stainless steel.

The intense heat of fiber lasers, combined with injected air, creates cuts without producing an oxide formation on the cut surface. This means that secondary cleanup operations are significantly reduced or even eliminated.

As any fabricator using nitrogen will tell you, it is a costly gas. In some instances, the cost of the gas alone can be as high as 90 percent of the total operating cost. Air is considerably less expensive than both nitrogen and oxygen.

Another advantage of air is the faster cutting and increased throughput it delivers. Cutting tests on the full range of materials and thicknesses prove this out.

For example, for material thicker than 10 gauge, tests have shown that nitrogen produces faster cuts, but in the mild steel range of 10 gauge (0.135 inch) and thinner, air is roughly 3 percent faster than nitrogen. In the stainless steel range from 0.750 in. down to 20 gauge (0.036 in.), air is about 22 percent faster. In the aluminum range from 0.190 in. down to 0.032 in., air is approximately 14 percent faster.

3. When Should Air be Used as an Assist Gas in Laser Cutting?

Today businesses are scrutinizing all areas of the operation to cut costs and boost productivity. For fabricators, this puts the shop floor under a microscope.

Something as common as air can deliver measurable cost and productivity improvements. While air is generally used to cut thin material, most stainless parts, especially those used in assemblies, are candidates for air-assist laser cutting.

While clearly not the best gas in all instances, generally speaking, air produces a laser-cut edge quality that is at least comparable to parts cut with oxygen or nitrogen. In fact, if one were to label nitrogen edge cut quality as a 10, then the edge quality resulting from an air-assist cut would be about an 8. Air-assist edge quality is more than satisfactory for most powder coatings to adhere to, eliminating the need for secondary cleaning operations.

Still there are times when nitrogen remains the best gas choice. Nitrogen produces a cleaner cut, and those serving customers throughout the food processing and aerospace industries should continue their use of the gas.

Additionally, some cosmetic parts cannot show any blemish whatsoever. Again, these types of parts would not be candidates for air-assist cutting.

Is It for You?

So is air the best choice for your laser cutting operation? The short answer is, of course, maybe. It all depends on the industries you serve and how important edge quality is to you and your customers.

The bottom line is that when edge quality is absolutely critical, nitrogen remains the best option. It produces cooler cuts and is an inert gas, meaning that there is no chemical reaction when cutting stainless steel. This prevents oxidization from occurring, leaving a clean, shiny edge that eliminates secondary descaling operations.

What about setup cost? Switching your laser cutting operation to air is relatively easy and cost-effective. Even most older-model lasers can be adapted to cut with air. Although an initial investment for the proper equipment is necessary, a fabricator that taps air as an assist gas should be able to generate sustainable cost savings while boosting productivity.

While air is certainly not the optimal assist gas in all cases, it is an efficient and cost-effective alternative for many. Take a look at the parts you cut, and investigate how much you are spending on assist gas. Run some tests and determine for yourself if the answer to increased productivity and profitability isn&#;t literally all around you.

Putting Air to Work

Doyle Equipment Manufacturing, Quincy, Ill., makes dry fertilizer blending, conveying, tending, and spreading equipment for the agricultural industry. Primarily processing stainless steel, more than 90 percent of the parts are cut on lasers. Both nitrogen and air are used, with about one-third of all cutting (both mild and stainless steels) relying on air as the assist gas.

Stuart Rumple, Doyle&#;s production manager, said the main concern about using air-assist during laser cutting was the weld quality of the cut part. Customers expected a nice, clean edge for a good weld.

When they saw the result of the air-assisted laser-cut edge on materials 0.105 in. and thinner, they didn&#;t have to worry. The fiber laser delivered edges that weld up &#;perfectly,&#; Rumple said.

&#;While we&#;ve successfully cut stainless material up to 1&#;2 in. using air, we generally find that thicker cuts are best-suited for nitrogen,&#; he said. &#;That said, we utilize air on a regular basis and have found the cost savings to be immense. Air-assist allows us to run our machines at less than $4 per hour, which equates to about a 90 percent savings over our CO2 laser and about 75 percent less cost than using nitrogen on the same machine.&#;

Contact us to discuss your requirements of Laser Air Compressor. Our experienced sales team can help you identify the options that best suit your needs.