There is no doubt that tube laser cutting has transformed the way many manufacturers process tube, box section and structural profiles. The ability to combine cutting, drilling, notching, coping and weld preparation into a single automated process can significantly increase productivity whilst improving consistency and reducing lead times. Tube lasers also offer the flexibility to process a wide range of profiles and materials with minimal setup times, making them an increasingly attractive investment for fabricators looking to modernise their production capabilities.

However, like any capital investment, tube lasers are not without considerations. The initial purchase price can be significant, particularly for larger machines equipped with automatic loading systems, bevel cutting capability and full production automation. Workshop space requirements must also be carefully assessed, as longer bed lengths and material handling systems can substantially increase the overall installation footprint. For businesses processing only small quantities of simple cut-to-length components, conventional sawing may still represent a more economical solution.

Ultimately, the suitability of a tube laser depends on production volumes, component complexity and long-term manufacturing objectives. For many businesses, the productivity gains, labour savings and reduction in secondary operations mean that a tube laser can deliver a compelling return on investment and become a key driver of future growth.

The Morgan Rushworth tube and section laser range covers everything from compact tube processing through to high-volume production and heavy structural sections. Choosing the right range largely depends on the size and type of profiles you need to process, your production volumes and the level of material handling required.

Fibre tube lasers can cut round, square and rectangular tubes as well as angle, channel, beams, RHS/SHS, open profiles and custom extrusions.

They’re suitable for mild steel, stainless, aluminium and many non-ferrous materials.

While some machines are better suited to one profile than another, in general a Tube Laser can cut virtually any profile that can fit inside the chuck.

Cutting thickness depends on laser power, typically ranging from thin-wall tubing up to heavier structural sections. For example, 2–3 kW lasers handle most fabrication work, while higher-power models tackle thicker walls at faster speeds.

Higher power machines can cut thicker materials faster, increasing throughput and reducing cost per part. While there can be a tendency in the market to encourage higher kW power, there’s a diminishing returns on higher power, and what can saved on cutting time, could be lost on higher running costs, and initial purchase costs.

Typical Maximum Cutting Capacities
Actual cutting performance will vary depending on material grade, assist gas selection, cutting quality requirements and machine configuration.

Yes. Modern CNC tube lasers include adaptive clamping and support systems that stabilise open profiles throughout the cutting process, allowing accurate cutting of angle, channel, I-beam and similar shapes.

Many machines include bevel-cutting capabilities, allowing chamfers and weld-prep angles to be cut directly into the profile.

This reduces downstream operations and improves fit-up accuracy for fabrication and structural work.

A tube laser can replace multiple conventional fabrication processes, including bandsawing, drilling, punching, plasma cutting, marking out and some machining operations. By producing finished components directly from CAD data, manufacturers can reduce handling, improve repeatability and significantly shorten production times.

A tube laser can often eliminate or reduce:

• Sawing / Cutting
• Drilling
• Punching
• Plasma cutting
• Marking out
• Milling
• Notching
• Bevelling
• Deburring
• Manual grinding
• Jigging and fit-up operations

In many fabrication environments, a tube laser can effectively replace traditional bandsaw cutting and cold sawing operations. Whilst saws are typically limited to cutting material to length, or to an angle, a tube laser can produce fully finished components in a single automated cycle. As well as cutting round tube, box section, channel, angle and structural profiles to size, a tube laser can simultaneously produce slots, holes, coping features, mitres, cod mouth joints and other complex geometries without requiring additional handling.

By consolidating several manufacturing steps into one process, manufacturers can significantly reduce labour requirements, minimise work in progress, improve dimensional accuracy and increase throughput. This is particularly advantageous for businesses processing repeat components or producing fabricated assemblies where reducing lead times and improving consistency are key objectives.

In many applications, Tube lasers are capable of producing accurately positioned holes, slots, elongated apertures and complex cut-outs directly into tube and section profiles during the cutting cycle. This often removes the requirement for separate drilling, punching or machining operations.

As components are processed directly from CAD or nesting software, hole positions are highly repeatable and do not rely on manual setting out or operator interpretation. For manufacturers producing handrails, agricultural equipment, architectural metalwork, furniture, structural assemblies or chassis components, this can substantially reduce production times whilst improving overall quality. Eliminating secondary drilling operations also reduces component handling and helps streamline workshop workflows.

One of the most significant productivity benefits of tube laser technology is its ability to improve component fit-up prior to welding. Accurate coping profiles, mitred joints and interlocking features allow fabricated assemblies to be positioned quickly and consistently, reducing the time spent adjusting and preparing parts.

Better fit-up typically results in improved weld quality, reduced distortion and less requirement for grinding or corrective work. For manufacturers producing welded assemblies in volume, this can translate into substantial labour savings and increased workshop capacity. In many cases, businesses investing in tube laser technology find that the benefits extend far beyond the cutting process itself, positively impacting fabrication, assembly and finishing operations throughout the production cycle.

One of the greatest advantages of tube laser technology is its ability to consolidate several conventional fabrication operations into a single automated process. Depending on the application, a tube laser can often replace cutting, drilling, punching, notching, marking out and some secondary machining operations.

Components can be produced directly from CAD data, complete with holes, slots, copes, cod mouth joints, mitres and interlocking features, leaving the machine much closer to a finished state. This reduces component handling, minimises work in progress and shortens production lead times.

Many manufacturers find that investing in a tube laser not only increases cutting capacity, but also improves efficiency throughout the workshop by reducing bottlenecks, simplifying material flow and freeing up labour for higher-value activities such as assembly and welding.

Tube-specific CAD/CAM systems generate cutting paths, optimise nesting, apply kerf compensation and position features around the tube circumference. These programs integrate directly with the machine controller for smooth workflow. Examples include Lantek Flex 3D and Sigmanest.

The most common assist gases are:

Nitrogen

Produces clean, oxide-free cut edges and is widely used for stainless steel and aluminium.

Oxygen

Provides faster cutting speeds in mild steel and thicker materials.

Compressed Air

A cost-effective alternative increasingly, as only a compressor is required, rather than bottled gases.

The choice depends on material type, thickness and finished part requirements.

For many manufacturers, an on-site nitrogen generator can significantly reduce operating costs compared to bottled or bulk gas supplies.

Nitrogen generation also provides greater supply security and predictable running costs.

Our team can assist with specifying the perfect size generator to suit your laser cutting requirements.

While most of our range comes with a level of automation in terms of loading or unloading, our Morgan Rushworth XTC can be supplied as a fully manual loading system if required. This is perfect for small-batch part cutting, where the machine isn’t going to be in use all day long. This reduces the cost of the machine, making it more worthwhile in production environments where you don’t have the volume for a fully automated system, but in-house capabilities are extremely beneficial.

This gives you the best of both worlds, in-house capabilities, at a more affordable price-point for the volume of use.

However we would say that almost every customer we talk to about tube lasers quickly realise that they’ll be able to keep their tube lasers busy enough to make automation worthwhile – especially when the other local businesses find out you now have one too!

Many tube lasers offer either semi-automatic or fully automatic loading, unloading, profile support, part sorting and continuous cutting cycles.

Automation greatly reduces manual handling and increases overall productivity. A bundle of raw material can be added to the machine, and then it can be left to it’s own devices, producing perfect, accurate parts, ready for the next step in the process, while the operator gets on with other tasks.

The amount of workshop space required for a tube laser depends not only on the machine itself, but also on the type of material being processed, the maximum tube lengths handled, and the level of automation incorporated into the system. Whilst the machine footprint is an important consideration, manufacturers should also allow sufficient space for loading, unloading, maintenance access and operator movement around the equipment.

Long-bed tube lasers designed to process full-length 6 metre, 9 metre or 12 metre profiles will naturally require a greater overall installation area. Particular attention should be given to the infeed and outfeed zones, as these areas need to accommodate the full length of raw material entering the machine, as well as the finished components exiting the cutting area. Depending on part geometry and production volumes, additional space may also be required for sorting, stacking or downstream fabrication operations.

Automated loading and unloading systems can further increase the overall footprint, particularly in terms of machine width. Bundle loaders, automatic magazine systems and material handling conveyors are typically positioned alongside the machine and can significantly expand the installation envelope. However, whilst these systems require additional floor space, they can substantially improve productivity by reducing manual handling, minimising idle time and enabling unattended or lights-out production.

For this reason, it is often beneficial to consider the tube laser as a complete production cell rather than simply evaluating the dimensions of the cutting machine itself. At Selmach, our specialists can review your workshop layout, production requirements and material flow to help determine the most suitable machine configuration and ensure sufficient space is available for efficient operation, maintenance access and future expansion.

A quality tube laser supplier should provide:

• Installation
• Operator Training
• Technical Support
• Preventative Maintenance
• Spare Parts Availability

Here at Selmach we offer all of this to our customers – we can also offer Service Contracts for further piece of mind too.

Key factors include the types of profiles you cut, wall thicknesses, material volume, automation needs, available space and budget. If you’re regularly cutting small parts from large tubes, you want a machine that can quickly process these, with high levels of automation. If you’re processing long, uncomplicated or irregular sections, you may benefit from a machine with semi-automatic loading, and prioritise chuck size.

Selmach’s team can help match machine specifications to your workflow.

Tube lasers offer significantly higher accuracy, cleaner edges and repeatable tolerances than tube plasma. They eliminate the distortions associated with mechanical cutting, and require little to no post-processing before welding or assembly.

Compared to sawing, it eliminates any human error from measuring the length of stock to cut, and ensures a perfectly square cut each and every time.