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Falcon FF airbag laser cutting machines

Zenna Laser develops laser cutting machines for flat fabric airbag production. The systems are designed for manufacturers that need accurate contours, stable cutting quality and a high level of automation in technical textile processing.

The Falcon FF is developed specifically for single-layer flat fabric airbag cutting. It combines continuous material handling, high-speed laser cutting and controlled process automation in one compact production system.

By using laser cutting instead of mechanical tooling or conventional multilayer cutting methods, manufacturers can reduce changeover time, improve flexibility and lower dependency on manual handling.

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Laser cutting for flat fabric airbag production

The Zenna Laser Falcon FF 20/2600 is a high-speed laser cutting solution specifically developed for single-layer flat fabric airbag production. The system combines continuous textile processing with high cutting accuracy and excellent repeatability, making it suitable for industrial airbag manufacturing environments.

Equipped with three high-power lasers, the Falcon FF continuously cuts moving fabric with minimal free space between nesting repeats. This results in high material efficiency, accurate contours and optimised production throughput.

Compared to traditional multilayer laser systems, the Falcon FF offers a more agile and flexible production method for flat fabric airbags. It is especially valuable for manufacturers that need shorter changeover times, smaller production batches, lower labour dependency and more flexibility for small orders without additional tooling cost.


Designed for speed, accuracy and repeatability

The Falcon FF 20/2600 delivers consistent, high-speed cutting for PET and technical airbag materials. Static laser scanners, optimised process control and automated handling support precise contours, short cycle times and reliable output.
Single-layer processing removes the need for separation foil and bottom paper, reducing consumables, handling and downstream work. Protection windows and improved smoke extraction help reduce cleaning and support higher uptime.

Automated material handling for fabric cutting

The Falcon FF combines laser cutting with automated roll handling, material verification and waste separation. Operators load the roll and identify the material; the system manages rewinding, turret rotation and preparation for the next job.
Controlled feeding and synchronised fabric transport keep flexible textile materials stable during production. This improves changeover time, batch flexibility and repeatable cutting quality with minimal operator involvement.

Vision systems for alignment and quality control

Vision technology supports alignment, inspection and process control in flat fabric airbag cutting lines. By detecting edges, reference points or patterns, the system can correct the cutting path before processing starts.
This improves cutting precision, reduces rejects and helps maintain consistent quality in automated production.


Features & benefits

Single layer laser cutting is gaining popularity versus the traditional Multi-layer laser lines, because of the following benefits and savings:

  • Excellent cutting results on PET material.
  • Saving on separation foil and bottom paper.
  • Significant labor saving on separation and foil removal.
  • Big improvement on flexibility, batch size and change-over time.
  • Excellent tool for small orders at no extra cost.
  • Saving on floor space, only 11 m length versus 30 m long ML-lasers.
  • Similar or higher output.
  • No reflection, better smoke extraction system.
  • Simple maintenance.
Falcon FF 20/2600


Built for industrial airbag manufacturing

The Falcon FF 20/2600 is built for demanding industrial airbag manufacturing environments where uptime, process reliability and operational efficiency are critical.

Compared to conventional multilayer laser lines, the Falcon FF requires significantly less floor space. The machine occupies only approximately 11 metres of production length, compared to around 30 metres for conventional multilayer laser systems, while achieving similar or higher output levels.

The compact layout reduces the required production footprint, while the automated single-layer process supports lower labour requirements, simplified maintenance, improved smoke extraction and faster changeovers. This makes the Falcon FF a strong solution for both high-volume production and smaller orders with frequent product variation.

Zenna Laser Solutions also develops client-specific laser cutting solutions for different fabric widths and production requirements. Systems are available for narrow web applications up to 500 mm, wide web applications up to 1,500 mm and XL-wide web applications up to 4,000 mm.

Depending on the application, cutting lines can be equipped with one to six lasers, integrated vision systems, robotic product handling, additional automation modules and compact second-platform configurations for chillers and cabinets.



Discuss your FF airbag cutting requirements

Looking for a faster, more flexible and highly automated solution for flat fabric airbag cutting?

Zenna Laser Solutions develops laser cutting systems tailored to specific production requirements, material characteristics and automation goals.

Discuss your application with our specialists to explore technical machine concepts, sample cutting tests, production optimisation opportunities, vision and automation integrations, and custom machine configurations.

Contact us to discuss your FF airbag cutting requirements and discover the most efficient solution for your production environment.

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