The Benefits of Laser Cutting Over Other Metal Cutting Methods
- 20-05-2025
- Featured Products
When you're working with metal, the cutting method you choose isn’t just a technical decision – it’s a business one. The right approach affects everything from finish quality and turnaround times to production costs and design freedom. Although tried-and-tested processes like oxy-fuel, shearing, turret punching, plasma and waterjet cutting all have their uses, there’s a reason laser cutting continues to rise through the ranks.
It's not about writing off the old favourites – after all, Morgan Rushworth continues to supply machinery for all of them – but there's no denying that laser cutting has become the method of choice in sectors where precision, speed and consistency are non-negotiables.
Why laser cutting still leads the pack
High accuracy
Laser cutting excels in applications where intricate detail, clean finishes and repeatable accuracy are essential. The ability to cut complex contours with tight tolerances makes it especially popular in industries such as electronics, automotive, architectural metalwork and aerospace. But it’s not just about accuracy.
Low distortion
Because laser cutting applies focused heat to a small area, it minimises distortion – even on thin sheets. The result is a cleaner edge with little to no burring, reducing the need for time-consuming post-processing. It also gives fabricators the flexibility to cut, mark and engrave in a single setup, which can make a huge difference to production efficiency and cost.
Easy automation
For companies needing to scale up or handle varied production runs, fibre laser machines also lend themselves well to automation, further improving turnaround times and reducing operator intervention. Laser cutting systems also frequently incorporate automated loading and unloading functions, which not only speed up production but also improve workplace safety through reduced manual handling and contact with potentially sharp edges.
What about other metal cutting methods?
Every cutting method has its place. That’s why Morgan Rushworth continues to supply a broad range of machines beyond laser systems — from hydraulic guillotines and plasma tables to CNC punches and traditional oxy-fuel kits. Understanding the strengths and limitations of each method helps manufacturers choose the best fit for their specific job.
Oxy-fuel cutting: unmatched thickness handling
Oxy-fuel cutting remains the go-to option for very thick mild steel. It’s robust and cost-effective – but not ideal for detail work or thin sections, where warping and rough edges can become a problem.
Mechanical cutting: straightforward and fast
Shearing, punching and sawing still offer speed and simplicity for basic shapes and straight lines. They’re excellent for stock preparation and high-volume production where fine detail isn’t required. But burrs, deformation and tool wear can reduce the quality and consistency of the finish — especially on thicker or more complex jobs.
Plasma cutting: powerful and affordable
Plasma has carved out a strong niche for itself, being faster, more versatile and less expensive than laser. But while it's quicker on thicker metal, it can’t match the edge quality or fine detail of a well-calibrated laser system and still leaves a heat-affected zone to manage.
Waterjet cutting: clean, cold and versatile
Waterjet is a brilliant option for cutting sensitive materials, multi-layer composites or where zero heat distortion is critical. It can slice through almost anything with superb edge quality.
The downsides? Waterjet cutting is expensive to install and maintain. For a start, the location of the waterjet cutter must include drainage and water treatment systems to keep the area clean and dry and to prevent contamination of water sources. It also needs to be partitioned off to prevent overspray to other areas, with access areas within and without the partitioned area adding to the overall footprint.
Maintenance costs are also a significant factor. A waterjet system includes a larger number of consumables and wearing parts compared with other systems, so the cost of replacement parts and downtime must be taken into consideration. Downtime will also extend to the time required to regularly drain the system and remove accumulate sludge, while disposal of this waste product is another concern.
Turret punching: speed of repetition
While laser cutting will always win hands-down over punching for general cutting versatility, there are still some instances where a turret punch has the edge. For example, a turret punch can be used to form profiles such as lugs and emboss profiles.
There’s also the challenge of speed. Faced with a long cut, laser will always be faster, but where a large number of holes must be punched repetitively, assembling the punching dies in a cluster punch takes a turret punch’s speed of productivity far beyond anything that laser cutting could reach.
Why laser often comes out on top
While each cutting process has its strengths, laser cutting consistently strikes the right balance between precision, efficiency and versatility. It’s fast enough for short lead times, accurate enough for fine detail, and clean enough to reduce rework — all without compromising on repeatability.
If you’re cutting thin to medium gauge metals, working on detailed designs, or simply looking for a process that delivers high-quality results with minimal cleanup, laser is hard to beat. It’s a natural fit for modern fabrication environments, where consistency and speed matter just as much as craftsmanship.
And with today’s fibre laser systems offering lower running costs, higher cutting speeds and increased reliability, the return on investment has never been more compelling — especially when backed by a trusted name in the industry.
Trusted expertise from a long-standing name
With so many options available, it's not always easy to know which technology is the right investment — especially when margins are tight, and demand is high. That’s where experience counts.
Morgan Rushworth has been part of the UK’s metalworking landscape for over 150 years. Our expertise spans the full range of cutting methods, but our latest fibre laser cutting machines represent the cutting edge of what’s possible in modern fabrication – combining speed, precision and automation in a single platform.
If you’re exploring new ways to boost capacity, improve edge quality or expand your range of services, it might be time to see what laser cutting could do for you.
To learn more about Morgan Rushworth’s laser cutting systems — or to discuss the right solution for your operation — visit www.morganrushworth.com or speak to our technical team today on 01785 508028.