A true 3D cutting head and a four-chuck system, the Mazak 3D Fabri Gear III and the Mazak FG-220 DDL transform the efficiency of tube laser manufacturing.
The 3D Fabri Gear line was introduced in 1999 and since then Mazak has continued to advance their 3D laser-cutting technology.
The Fabri Gear III comes in two sizes the Mazak 3D Fabri Gear 220 III and the Mazak 3D Fabri Gear 400 III both featuring a six-axis laser available as a 2.5kW or a 4kW. The length of the material is 8,000 mm for both machines, but the Mazak 3D Fabri Gear 400 III processes rounds up to 406.4 mm while the Mazak 3D Fabri Gear 220 III is 220 mm round capable.
Mazak has engineered a proprietary 3D cutting head that maximizes flexibility and the range of movement which expands the range of applications possible. User defined cut angles are useful for weld prep and getting the highest accuracy for easy fit-up assemblies.
While the Fabri Gear isn’t the only tube laser on the market, most tube lasers only utilise a two-chuck system. The Fabri Gear’s four-chuck system allows full control of raw material and finished parts throughout the process, especially important when making long, large and heavy finished parts.
The four-chuck design is ideal for processing structural materials such as I beam, H beam, angle iron, c channel, HSS, along with other user defined materials.
Common with structural materials is inconsistent shapes like it being bowed, twisted or misshapen which makes the four-chuck system vital.
Features like the self-centering of the opening and closing of the chucked tube supports to keep the material in line, and machine functions to find the center of the material before cutting, all help to make very precise parts.
Mazak leverages automation to load material, cut parts, tap, chamfer holes and unload finished parts all with little to no wait time from simultaneous operations.
Using mechanical dies and punches in a multi-step process to make finished parts which takes a lot of time and has potential for error. Having the Fabri Gear’s ‘all-in-one’ process saves a number of hours and offers a better chance of making consistently accurate parts.
The Fabri Gear is incredibly unique with built in tapping, up to 6 different taps, and the six-axis head allowing for 3D geometry from beveled and mitered end cuts to countersink holes.
Other notable features include a measuring system that automatically measures material length through a sensor and another sensor in the cutting area that measures the material and compensates for distortions.
Fabri Gear is used in many industries, not only to make parts for buildings and infrastructure, but also to make the machines that are used on the construction sites to do these jobs. From cranes and boom lifts to scissor lifts and fork trucks, this equipment has many parts that are or could be made from tube or other structural shapes, such as angle iron and C-channel that can be processed on the Fabri Gear.
Not only has Mazak been an innovator in 3D laser cutting but also in laser generators, direct-diode laser (DDL). Mazak’s next generation of the Fabri Gear machine now utilizes DDL technology in the Mazak FG-220 DDL. This laser source delivers high performance and reliability compared to CO2, fiber and other solid-state laser generation systems.
The Mazak DDL generator offers 45 percent more energy efficiency compared to previous laser sources. It also allows for higher energy absorption rates and increased power density. Comparing the modes, or beam diameter, the DDL has a 40 percent increase in power density over fiber. This is thanks to a smaller beam diameter that is able to offer more intense light, which ultimately increases cutting speed.
The smaller beam diameter also creates a reduced heat-affected zone, in part because the DDL beam is a 10th the size of a CO2 beam and because its cutting speeds are faster. Both of these beam characteristics result in less heat needed to cut the material and less time that the edge of the material is being touched by the laser’s extreme heat.