FlexCutter MT500

The ZennaLaser FlexCutter MT500 is a powerful and configurable laser cutting machine designed for abrasive materials with a width of up to 500 mm. It is a versatile laser system capable of cutting all possible hole patterns and shapes, including discs with multi-holes, sheets, and triangles. With its configurable modules, the FlexCutter provides the solution to automate and enhance the efficiency of any abrasives converting tool.

In addition to discrete parts, the FlexCutter, can be configured to produce sheet- and disc rolls, as well as fine grit daisy discs on a liner. Besides shapes, the FlexCutter can cut a large variety of materials, such as paper, film, PSA backing, and grits ranging from P36 to P2000. In summary, this flexible FlexCutter is the perfect production tool for both small and large batches, capable of switching between orders without stopping the line.

The working area of the FlexCutter series can vary with a maximum material width of 500 mm. For wider materials from 600 mm up to 1,750 mm, Zenna offers the MultiCutter series with two or three lasers.

There is a wide range of laser power sources available, varying from 200 watts to 2,500 watts. The more laser power, the higher the output, resulting in a line speed of 5 m/min to 70 m/min. The coarser the grid, the more laser power is needed for a high cut quality.

The FlexCutter benefits from the powerful ZocuPRO software control, also used in Zenna's larger laser cutting lines. It includes a user-friendly CAD module for designing shapes or importing existing shape drawings (dxf) and can communicate with ERP systems. All designs and laser parameters are stored in automated databases, making the FlexCutter very easy to operate. One day of training is sufficient to operate this laser machine. ZocuPRO enables you to process a wide range of materials and cut an unlimited selection of shapes and patterns while cutting the material 'on the fly.'

Advantages of the FlexCutter:

Less than 3 seconds of changeover time from ‘order to order’.
Cutting any shape and any hole pattern without investing in tools.
Ability to cut multi-hole discs and sheets.
High cutting accuracy and edge quality, from the first to the last part.
Low maintenance costs compared to alternative cutting methods.
High degree of automation, requiring minimal labour.

Because the FlexCutter is configurable, it can meet any client requirement. The following options are available:

A double unwinder for even faster material changes.
Laminating module for adding a liner on a PSA backing.
A MultiPicker robot to make stacks, including a counter.
A (dual) rewinder for making sheet and disc rolls.
An accumulator module to exchange a product roll for cores, while cutting continues.

Process description of the FlexCutter:

A roll of abrasive material is loaded on the pneumatic unwinder shaft, after which it is connected to the end of the previous material on a splice station. From the splice station the material is transported automatically via a dancer into the cutting station. The entire cutting process runs continuously 'on the fly'.

When the material enters the cutting station, the holes are cut first and the pips fall into a bin beneath the cutting surface. Secondly the shapes are cut while supported on the M-belt conveyor.

After the cutting station, the material moves forward on the M-belt conveyor, and a bull-bar separates the trim material from the cut parts. In the case of discrete discs or sheets, the trim material is stripped off and wound onto the waste winder. The separated parts remain on the M-belt conveyor and can be collected by hand. For automatically stacking of discrete parts, the optional MultiPicker robot is placed behind the cutting stage.

Orders can be created, edited and selected on the HMI. All shape drawings and material properties are stored in database libraries on the ZocuPRO software platform.