Benchmarking Productivity and Cost-effectiveness of Multi-kW Laser Cutting across Industrial Cutting Technologies

Laser cutting is widely employed in sheet metal processing due to its high productivity and flexibility, enabling tailored industrial solutions. However, its efficiency decreases when processing thick-section metal sheets, where alternative cutting technologies are often preferred. The reduction in cost-per-kilowatt and laser source prices, driven in particular by Asian manufacturers, has contributed to the development of ultra-high power laser cutting systems, enhancing the technical and economic feasibility of laser technology relative to established cutting methods for high thickness applications. This study presents a comparative analysis of current industrial technologies for processing thick-section metals. Industrial datasets were collected to evaluate productivity for laser, plasma arc, oxyfuel, and abrasive waterjet cutting. Findings indicate that plasma arc cutting maintains high productivity across a wide thickness range. Laser systems potentially achieve comparable speeds at power levels above 30 kW, while economic competitiveness primarily depends on reductions in the laser machine investment cost.