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OPW airbag laser cutting machines

The Zenna Laser Falcon OPW 25/3000 is a highly automated laser cutting system developed specifically for one piece woven (OPW) airbags. Designed for maximum throughput, positioning accuracy and reliable production output, the Falcon OPW combines high-power laser technology with advanced automation and inline quality control.

With three 2.5 kW laser sources, automatic roll handling and integrated vision positioning, the Falcon OPW 25/3000 is built to support demanding automotive airbag production environments with minimal operator involvement.

Laser cutting for one piece woven OPW airbags

Laser cutting plays a critical role in the production of one piece woven airbags. OPW materials require extremely accurate cutting due to integrated woven chambers, complex contours and strict dimensional tolerances. Even small deviations can directly affect downstream assembly and airbag performance.

The Falcon OPW 25/3000 is engineered to process OPW materials with consistent accuracy and stable cutting quality. Its inline vision module supports positioning and material recognition before cutting starts, ensuring that every individual airbag is aligned correctly.

The system supports both fixed frame and hybrid MDC cutting profiles. It can also process double, mirrored OPW airbags in one long marker, helping manufacturers increase output efficiency within a controlled production flow.

Features & benefits

Turret unwinder as standard for safe and fast roll changes.
Laser scanners are static positioned to secure a high accuracy and have a special Zenna designed protection window against smoke and debris contamination, increased uptime, no maintenance.
Fully automatic roll Feed-In system for fast roll changes within 3 minutes.
Vision recognition (seam, fiducial, holes) for accurate positioning of each individual airbag
Cutting profiles as ‘fixed frame’ or ‘hybrid MDC’ are possible.
Ability to cut double (mirrored) OPW in one long marker.
Ability to make manual offset adjustments per airbag and even per section.
Highest cutting output with three 2.5 kW laser sources.
New STM-belt, designed for less wearing, no reflection and less fusion.
Removal system for waste and rejected parts.

Built for complex airbag production requirements

OPW airbag production involves complex geometries, seam positions, holes and critical cut-to-seam tolerances. Manufacturers require cutting systems that can maintain repeatability at high production speeds while handling different material structures and product variations.

The Falcon OPW platform is developed specifically for these production requirements. Vision recognition can detect seams, fiducials and holes to position each individual airbag accurately before cutting. Manual offset adjustments can also be made per airbag and even per section, giving production teams precise control when fine-tuning the process.

The machine delivers high cutting output with three 2.5 kW laser sources. Static-positioned laser scanners contribute to high cutting accuracy, while special Zenna-designed protection windows protect the optics against smoke and debris contamination. This helps increase uptime and reduces maintenance requirements.

The Falcon OPW combines automatic roll handling, vision-guided alignment and controlled laser processing in one workflow. After a new roll is loaded and identified by barcode, the system automatically feeds the correct material into production, with roll changes possible in approximately three minutes.

Before each cutting cycle, the integrated vision system detects seams, fiducials, holes or other material features to align every airbag section accurately and compensate for small variations. Controlled process settings, improved smoke extraction and a newly developed STM belt support clean edges, stable cutting quality and easier maintenance during long production runs.

The Falcon OPW 25/3000 combines automation, laser processing, material handling and quality control in one integrated production line. From roll loading to finished cut parts, the system controls material feeding, vision positioning, laser cutting, inline inspection, scrap removal and part stacking or conveyor output.

The machine can be extended with pick-and-place stacking, inline inspection for holes, dimensions and seam distance, and inkjet marking for unique IDs or twist lines. This reduces manual handling, improves repeatability and supports predictable production output with single-operator control under normal production conditions.

Developed for high-output OPW production

The Falcon OPW 25/3000 is built for manufacturers that need high output without losing control over cutting quality, positioning accuracy or process stability.

With three 2.5 kW laser sources, static laser scanners, automatic roll feed-in, vision recognition and integrated waste removal, the machine is designed to support demanding OPW production with short changeovers, high repeatability and minimal operator involvement.

The combination of controlled material handling, accurate vision alignment and high-power laser cutting makes the Falcon OPW suitable for large-scale automotive airbag production where uptime, quality and throughput are critical.

Develop your OPW cutting solution with Zenna Laser

Every OPW production environment has different capacity requirements, automation levels and product variations. Zenna Laser supports manufacturers with tailored OPW laser cutting solutions based on their production goals and material specifications.

In addition to the Falcon OPW 25/3000, Zenna Laser also offers the Falcon Allround for OPW and flat fabric cutting, allowing manufacturers to switch between OPW and FF airbag cutting on a single laser line.

Interested in optimising your OPW airbag production process? Contact Zenna Laser for technical advice, production testing or a customised machine concept tailored to your manufacturing requirements.