Enhancement of low power CO2 laser cutting process for injection molded polycarbonate

Mahmoud Moradi, Omid Mehrabi, Taher Azdast, Khaled Y. Benyounis

Research output: Contribution to journalArticlepeer-review

57 Citations (Scopus)
134 Downloads (Pure)


Laser cutting technology is a non-contact process that typically is used for industrial manufacturing applications. Laser cut quality is strongly influenced by the cutting processing parameters. In this research, CO2 laser cutting specifications have been investigated by using design of experiments (DOE) with considering laser cutting speed, laser power and focal plane position as process input parameters and kerf geometry dimensions (i.e. top and bottom kerf width, ratio of the upper kerf to lower kerf, upper heat affected zone (HAZ)) and surface roughness of the kerf wall as process output responses. A 60 Watts CO2 laser cutting machine is used for cutting the injection molded samples of polycarbonate sheet with the thickness of 3.2 mm. Results reveal that by decreasing the laser focal plane position and laser power, the bottom kerf width will be decreased. Also the bottom kerf width decreases by increasing the cutting speed. As a general result, locating the laser spot point in the depth of the workpiece the laser cutting quality increases. Minimum value of the responses (top kerf, heat affected zone, ratio of the upper kerf to lower kerf, and surface roughness) are considered as optimization criteria. Validating the theoretical results using the experimental tests is carried out in order to analyze the results obtained via software.
Original languageEnglish
Pages (from-to)208-218
Number of pages11
JournalOptics and Laser Technology
Early online date9 Jun 2017
Publication statusPublished - 1 Nov 2017
Externally publishedYes

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Optics and Laser Technology. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Optics and Laser Technology, 96, (2017)
DOI: 10.1016/j.optlastec.2017.05.022

© 2017, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/


  • Laser cutting
  • Statistical investigation
  • Modeling and optimization
  • Injection molding
  • Design of experiments


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