The Operating Costs of Laser Cutting Machines

Gas Consumption and Associated Costs

Gas consumption plays a major role in the operating costs of laser cutting machines, especially when it comes to processing different materials with precision and speed. Both fiber and CO2 laser systems rely on gases—either as assist gases for cutting or, in the case of CO2 lasers, as a core component of the laser generation process itself. Understanding which gases are used, how they’re delivered, and how much they cost is essential for managing expenses and choosing the right setup for your workflow.

Assist Gases

Assist gases are used in both fiber and CO2 laser cutting machines to remove molten material from the cut area, cool the work zone, and improve edge quality. The most common assist gases are oxygen, nitrogen, and, occasionally, compressed air.

Oxygen is often used when cutting mild steel. It supports the cutting process through an exothermic reaction, increasing cutting speed but leaving a rougher edge.

Nitrogen is preferred for stainless steel and aluminum, providing a clean, oxide-free edge. It’s more expensive than oxygen due to the higher pressure and volume required.

Compressed air, a cost-effective option, is suitable for thinner metals and offers a good balance of performance and cost, especially in light industrial use.

Gas consumption rates vary widely depending on material type, thickness, nozzle design, and cut speed. High-pressure nitrogen systems can consume several hundred cubic feet per hour, resulting in significant operating costs.

CO2 Laser-Specific Gas Requirements

Unlike fiber lasers, CO2 lasers require a mixture of gases—typically carbon dioxide, nitrogen, and helium—as the laser medium. These gases must be kept pure and at specific ratios to maintain beam quality and system performance. Over time, these gases degrade and must be replenished, either through sealed laser tubes (with finite lifespans) or by using a continuous-flow gas supply system. This adds another layer of recurring cost not present in fiber laser systems.

In addition to the laser medium, CO2 systems also use assist gases just like fiber lasers. However, because of the added complexity of maintaining the laser-generating gas mix, CO2 lasers typically incur higher gas-related operating costs.

Gas Delivery Systems

Whether using bottles, bulk tanks, or on-site generation, the choice of gas delivery system affects both convenience and cost. High-use operations may opt for centralized gas delivery with manifolded cylinder banks or bulk storage tanks to minimize downtime and reduce per-unit gas costs. Smaller shops may rely on standard high-pressure cylinders, which are easier to manage but more expensive per cubic foot of gas.

Regular inspections, leak checks, and pressure regulation are critical for maintaining system efficiency and avoiding waste, especially when using costly gases like high-purity nitrogen.

Gas consumption is a significant ongoing expense in laser cutting operations. Fiber lasers generally incur lower gas costs, relying solely on assist gases, while CO2 lasers face added costs for both assist gases and the laser medium itself. The choice of gas type, material being cut, and delivery method all influence total costs. Accurately accounting for these variables is essential for controlling overhead and optimizing production economics.