What Does a Laser Machine for Micromachining Cost?
An overview of the cost factors of laser machines and how machine pricing is determined
Dr. Marius Gipperich | 9th of February 2024 ᛫ 15 Min.
Investments in laser technology
Investments in new technology often pose challenging questions for companies, especially when they concern advanced equipment such as laser machines for micromachining. The key to success lies not only in knowledge about the technical advantages but also in a solid understanding of the financial aspects involved. Before investing in new technologies and machines, enterprises should answer a number of questions: what are the advantages of the new technology or machine? Will their utilization increase productivity or the quality of products? Can they help to serve new markets?
Of course, the costs of such an investment are also decisive. While the approximate costs of conventional tools such as milling machines are often well known in the industry, the knowledge level on laser micromachining solutions is significantly lower. This sometimes leads to customers being “negatively” surprised, when educating themselves on laser technology for the first time.
This article provides a detailed insight into the cost structure of laser machines and highlights the various factors which influence these costs.
Cost transparency in laser machine manufacturing – a “no go”?
Contrary to other industries, price transparency in engineering is not very widespread. Most companies still practice secrecy when it comes to their machines’ cost unless a customer officially requests a quote. In special purpose machine manufacturing this can be understandable, as the final cost depends largely on the customers’ needs.
In most cases, a rough price orientation can be provided nonetheless, if the fundamental machine parts required are known. It should be mentioned that the cost for comparable machines from varying manufacturers usually lies in similar orders of magnitude – at least as long as competition inside Germany or Europe is taken into account. As soon as a customer has quotes from two competing manufacturers, they will know the differences anyway, which is why we aim to be transparent from the start.
What determines the cost of a laser machine?
Like in almost all areas of life, when it comes to the cost of laser machines the old adage of “it depends” very much applies.
Simple laser marking machines with a nanosecond laser (power < 30 W, wavelength in the infrared range) are available for less than 100.000 €. This includes for example a laser scanner, a z-axis, a rotational axis and an enclosure with laser protection class 1.
Things are different when looking at the field of high-precision laser micromachining with ultrashort pulse laser beam sources. USP-machines enable the precise machining of workpieces to the nearest micrometer with nearly no thermal influence. Besides a costly femtosecond beam source, these require a precision axis system and a 3D-scanner. These components are complemented by a machine enclosure with laser protection class 1, X-ray protection and auxiliary assemblies. Even a compact – but fully-featured – USP laser machine like the RDX500 by Pulsar Photonics has a starting price of around 475.000 €.
When an even higher level of performance and flexibility are needed, Pulsar USP-machines with an extended configuration are available. For example, some machines enable the use of two working stations per enclosure which can be supplied by one or more high powered USP laser beam sources. In many cases, such high-end machines also integrate measurement technology for the observation and control of process and products. Solutions for automatic loading and unloading are available. One machine suited very well for these extended capabilities is the Pulsar Photonics RDX800.
If a truly fully automated USP production solution is needed, a specially constructed machine is usually necessary. These may come with automatic handling systems and measurement tools for a 100 % verification of products. Such a system also requires a software solution which is individually tailored to the customers use case. Pulsar Photonics serves this market with its fully automated laser machine P1000, which can be freely configured starting from around 1.000.000€.
How can a better understanding for these prices be achieved? The following section should help interested parties to obtain an understanding for the costs and to explain, what the main cost factors are for the individual assemblies of a laser machine.
The most important component assemblies of a laser machine and the most important development aspects for a machine project are:
- Machine technology
- Laser technology
- Measurement technology
- Engineering und other services
- Auxiliary units and automation solutions
The following section provides a rough estimate for each individual aspect using estimates for the categories and wholesale prices of selected components.
Machine Technology
This category includes all the base components without which an operation of the machine – independent of the specific machining job – would not be possible.
- Machine enclosure with load-bearing machine frame and bed made of granite for high precision and stability
- Electronic and electrical equipment including control cabinet and emergency stop system
- XY cross tables or portal systems for workpiece handling and positioning: small format cross tables for positioning in the single-digit micrometer range are available for as little as 30.000 €. However, in large format special machines these solutions can cost several hundred thousand Euros.
Total cost for machine technology: 100.000 €
Laser Technology
The laser technology is in many ways the heart of a laser processing machine. Consequently, the associated components consitute a large part of the total cost of the machine.
- Laser beam source:
The choice of laser beam source is central to the manufacturing processes the machine is capable of. Selecting a laser for ablating processes usually involves a trade-off between the required precision (dependent on pulse duration, advantage USP lasers) and productivity (dependent on power, advantage longer pulse lasers). Typical prices for these categories are:- Compact fiber lasers for marking systems suitable for production are available starting from 20.000 €, high-powered cw lasers are significantly more expensive at >100.000 €.
- Compact, open beam USP lasers suitable for production are available starting from 100.000 €. For higher powered units of 100 W and above, shorter pulse durations in the fs range, second wavelengths in the VIS or UV range, costs rise into the range of >200.000€. High powered USP laser beam sources cost several hundred thousand Euros.
- Processing head:
The processing optics turn the laser beam into a highly capable machining tool. They determine, which size and shape the beam cross section has in the processing plane and which structure dimensions and depths can be manufactured. Different optics can be utilized depending on the machining process. There are many options for fixed and drilling optics, 2D- and 3D-scanning systems, which are able to move the beam within the scanfield at speed of up to 30 m/s. Even simple marking systems are fitted with galvanometer scanners and focusing optics. Finally, there are significant differences in the price depending on the selected quality of such optics. - Beam control and shaping:
This is necessary to enable the laser beam to travel from its source to the processing head. It includes: fiber guided systems and open beam systems, switching devices, polarizers, expanders and collimators.
Total cost for laser technology: 150.000-200.000 €
Measurement technology
Laser machines utilize various measurement systems both in the preparation of processes (calibration), process and product monitoring as well as machine calibration and diagnosis. Common components and assemblies are:
- Camera-based measuring technology such as image processing for registration mark recognition or beam diagnosis
- Condition monitoring systems
- Powermeter
- Laser or confocal measuring technology
- Spectrometer for online process monitoring
- Inspection systems for 100 % control
The cost for individual sensors typically lies between a few hundred Euros up to the five digit range. The cost for integration, programming and testing usually exceeds the purchase price for the sensors. Pulsar Photonics laser machines for micromachining are developed with a base configuration of measurement technology. This includes camera systems for the precise positioning of workpieces, measurement and remote servicing, condition monitoring systems with a set of sensors, spacing systems and software-based solutions.
Total cost for measurement technology: 50.000-150.000 €
Engineering and ancillary services
Simply acquiring subsystems and component parts is not sufficient for the construction of a laser system. It is a complex project which requires clear planning and is realized in many subprojects. These include:
- Project management and work preparation
- Mechanical and electrical installation
- Calibration and parameterization
- Commissioning of technical processes
- Design and software development including a wide range of CAD-/CAM-processing and assistance solutions
- Technical documentation
- Financing, inventory management
- Entrepreneurial risk and revenue
Software development may be necessary depending on the complexity of the machine, solutions fit for production are not realistically achievable below 15.000 €. On the other hand, simple marking software solutions are available starting from a few thousand Euros. Customer-specific variants, licenses, CAD-CAM interfaces, ERP or PLS integrations can in some cases require a large subproject in the magnitude of >100.000 €.
Total cost for engineering und ancillary services: >150.000 €
Auxiliary units and automation solutions
Laser-based manufacturing processes often require additional systems. The same is true for automatic loading and unloading as well as the handling of workpieces within the machine.
Such systems can include:
- Handling systems, linear conveyors, sorting switches
- Roll-to-roll or conveyor systems
- Robots with effectors
- Vacuum/negative pressure units, filter systems, air compressors, flushing systems, climatization technology and cooling units
The exact configuration required can differ greatly depending on both product and process. A solid base equipment level of machines for laser micromachining without automation includes filtering and extraction systems, compressed air systems e.g. for the supply of process gas as well as units for cooling of laser beam source, optics, control cabinet and potentially the machine. This hardware is available starting from 50.000 €. If specialized systems are needed, costs can rise significantly.
Total cost for auxiliary units and automation solutions: starting from 50.000 € and as high as >500.000 €
Operating costs for a laser machine
The operating costs are an important element of the total cost of ownership of any machine and as such are highly relevant to the consideration of whether or not such a machine should be acquired.
The good news is: compared to mechanical alternatives, the operating costs of a laser processing machine are very low. The main reasons are:
- There is no tool wear and very little wear to the machine in general
- The process typically requires no cutting fluid (exception: waterjet-guided systems)
- Axes operate without lubrication to a great extent
- Servicing costs are low
On the whole, only electricity, compressed air and in some cases coolant are required. The extraction systems require cleaning and replacement of filter mats. In the case of our high-powered production machines with kW-range laser sources, protection glass has to be replaced in regular intervals at a low cost of a few hundred Euros, for larger and more expensive windows a few thousand Euros. The labor cost for maintenance is comparatively low.
Which running costs are to be expected for a laser machine?
Total cost of a laser machine
In summary, the costs for laser machines are largely dependent on the application area. The largest factors are:
- Which laser beam source is suited for the application
- Optical setup: number of processing heads, necessity for special or multi-beam optics
- Size of workpieces and required precision
- Level of automation
When considering acquiring a USP laser machine for micromachining, one should expect the cost to start from 500.000 €. This is likely a bit higher than the cost of conventional machines utilizing chip-forming methods. In return, the laser opens up entirely new possibilities which are not achievable with conventional machines and ensures very low running costs.
Pulsar Photonics production machines always pass through a ramp-up phase in which different variants are produced or manufacturing quantity is not yet at production level. In this phase we are happy to assist with our own in-house machine outfit.
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Dr. Marius Gipperich
Dr. Marius Gipperich is key account manager at Pulsar Photonics. After studying materials science and engineering he earned a doctorate at the RWTH Aachen University, researching manufacturing technology and laser material processing. He has collected more than five years of practical experience in the area of laser technology.