How 4 BODOR 20kW Lasers Achieved 3x Cutting Speed with Mixed Gas
A fabricator running four BODOR 20kW lasers eliminated their grinding department and boosted output by 180% — all without changing a single laser.
The Challenge
A metal fabrication shop in Southeast Asia was running four BODOR 20kW fiber lasers on pure oxygen to cut carbon steel. Their main product line required 6mm black steel sheet, and every part needed grinding before it could be welded or painted.
- Cutting speed on 6mm: 2.3 m/min — they thought this was normal
- Edge quality: Heavy oxidation, rough surface, discoloration
- Grinding department: 6 full-time workers, every shift
- Monthly gas bill: ~$3,200 (liquid oxygen, bulk delivery)
- Rework rate: ~12% of parts rejected due to grinding errors
The Solution
LISHI LASER installed two mixed gas stations in One-to-Two mode — each station feeding two BODOR lasers simultaneously. The system mixes liquid nitrogen with a precise 5% oxygen blend using IGBT-controlled metering valves (±0.5% accuracy).
- Installation: 2 mixing stations → 4 lasers (one-to-two per station)
- Setup time: 3 days including on-site training
- Weekly consumption: ~3,200L LN₂ + ~170L LO₂ (all 4 machines)
- No modifications to the BODOR lasers — plug-and-play with existing gas inlets
Results: Before vs After
| Metric | Before (Pure O₂) | After (Mixed Gas) | Change |
|---|---|---|---|
| 6mm CS Speed | 2.3 m/min | 7.1 m/min | 3.1x faster |
| Edge Quality | Oxidized, rough | Silver-white, burr-free | Ready to weld |
| Grinding Workers | 6 full-time | 0 | Eliminated |
| Monthly Gas Cost | $3,200 | $2,100 | -$1,100/mo |
| Monthly Output | Baseline | +180% | Nearly 3x parts |
| Rework Rate | ~12% | <1% | Eliminated |
"The grinding department is now a storage room. Our welders say the fit-up is better because there's no oxidation layer to clean. We didn't change our lasers — we changed what flows through the nozzle."
— Operations Manager, Southeast Asia Fabrication Shop
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