High-laser cutting power added to existing fiber and plasma cutting capabilities.

The metal fabrication industry’s business case for high-laser cutting power has evolved over the years. In the early years of CO2 laser cutting, more power let you cut faster and thicker. Especially for service centre type businesses, a higher-powered laser broadened a shop’s capabilities and capacity, which in turn opened the door to new customers and markets.

Then in the late 2000s came the fiber laser and a whole new ballgame. Cutting thin stock, a fiber laser could run circles around a similarly powered CO2 laser. The fiber laser pushed the industry’s cutting capacity skyward, so much so that many shops struggled to feed the beast. Sure, a shop could automate the material handling, but even so, a laser that cuts extraordinarily quickly can overwhelm processes downstream, especially bending and welding. If a shop beefs up its cutting capacity only to shove the bottleneck downstream, what good is all that cutting power?

FMG Steel have invested in a Hugong HG 4020 20kW fibre laser, supplied and installed by TRM Supplies. The machine has been running since May 2024. The Hugong has a bed size of 4 000mm by 2 000mm and its power source is Maxphotonics

Turns out, all these assumptions might oversimplify the strategy needed to foster optimal throughput, especially once you take a deep dive into companies that have installed 10, 15, even 20 kW of fiber laser cutting power.

A prime example, FMG Steel has found plenty of good in more cutting power. On the shop floor sit two Hugong fiber lasers, one 4kW and the other a 20kW. To understand why the fabricator invested in such immense cutting power requires a closer look at the company.

FMG Steel was only established as a metal cutting and bending service centre just over two years ago when Glen Zeman’s father purchased a Hugong plasma cutter and threw him in the deep end by asking him to run the machine. Prior to that Glen had been working in his father’s foundry business so he had no experience in metal cutting, but learned fast.

The company’s first Hugong laser arrived in February 2024. It is a 4kW fiber laser with a bed size of 3 000mm by 1 500mm, purchased from TRM Supplies. On this machine the company mainly focuses around the 4mm mild steel mark but they do have plenty of options. For example, with oxygen they can cut up to 20mm

“The machine has a bed size of 6 000mm by 2 400mm and can cut up to 40mm thickness comfortably, so it is not small. We also added a flame cutting attachment that cuts up to 100mm thick. Initially we did get help from the suppliers TRM Supplies but then we had to run on our own. The machine served its purpose at the time and is still operating but not as much as it used to, since we have purchased a couple of fiber lasers.”

“Our first Hugong laser arrived in February 2024. It is a 4kW fiber laser with a bed size of 3 000mm by 1 500mm. We purchased the machine, again from TRM Supplies, because of our growth strategy. On this machine we mainly focus around the 4mm mild steel mark but we do have plenty of options. For example, with oxygen we can cut up to 20mm. But we all know that the thicker the material you try to cut the more finishing you will probably have to do. Rather stick to what it is known for – faster cutting than CO2 and less costs to run it.”

Adding press brake capability
“We knew from the beginning that a laser and a press brake fit like a glove in the type of business we wanted to operate. Without one or the other you are limiting your service offerings. Initially we purchased a 180 ton press brake and this was followed by a 100 ton machine. In September last year we installed a Yangli HB0 625 series servo hydraulic pump CNC press brake that has a bending force of 63 tons and a bending length of 2 500mm.”

Production Manager Richard Da Silva and Director Glen Zeman

“Buying a press brake for your metal service centre can help you achieve greater precision and better quality control over the pieces you create. But there are many other advantages, such as increased versatility, enhanced capabilities and others.”

“Then comes the capacity conundrum. In our short history we have gone past our expected levels. So we are adding a new Yangli HB02532 press brake. This time we have ordered a 250 ton with a bending length of 3 000mm, 8-axis machine and it will take us up to 4 machines on the floor. We are not in the league of bending large components but rather smaller ones and many of them.”

“Press brakes have so many applications that every day of your life you will see several products that have been directly or indirectly manufactured using this equipment. The extensive press brake applications are one of the main reasons that these machines find use in almost every industrial sector.”

FMG Steel was only established as a metal cutting and bending service centre just over two years ago when Glen Zeman’s father purchased a Hugong plasma cutter and threw him in the deep end by asking him to run the machine

Hugong 20kW fiber laser
“In the mean time we invested in a Hugong HG 4020 20kW fibre laser, also supplied and installed by TRM Supplies. The machine has been running since May 2024. The Hugong has a bed size of 4 000mm by 2 000mm and its power source is Maxphotonics.”

“We might not have bulked-up our bending department yet but you could say we have done just that in the fiber laser cutting department. Our 4kW machine gives us plenty of capacity but now the 20kW machine gives us the flexibility of plenty of extra capacity but also enhances our capabilities. For example, some of the plates that we were cutting on the plasma cutter can now be cut on the 20kW machine but a lot faster. Therefore our productivity increases.”

In December last year FMG Steel installed a Yangli HB02532 series 8-axis CNC press brake, supplied by TRM Supplies, that has a bending force of 250 tons and a bending length of 3 000mm

CypNest and HypCut nesting and cutting software
“The software packages that we are using are CypNest, a nesting software for sheet laser cutting CNC systems and HypCut, which has been developed for the sheet metal laser cutting. We could have gone for the well-known brands but they have become very expensive and these two – CypNest and HypCut – are both developed by the same developer and are lot more affordable and do the same operations.”

Tekenso’s eTrack
“On the quoting and invoicing side, we have signed up for Tekenso’s eTrack platform that gives us an effective management and oversight of various operational inputs from sales to pricing, orders outstanding, and tracking work-in-progress on the shop floor, to ensure the production and delivery of product is on time and within budget for the end-customer.”

In September last year FMG Steel installed a Yangli HB0 625 series servo hydraulic pump CNC press brake that has a bending force of 63 tons and a bending length of 2 500mm

“We are also doing a bit of fabrication for clients but it is not our focus.”

“I must make special mention about Richard who is on the shop floor making sure all the machines are running optimally and admin staff who makes sure all the administration functions are also running optimally. Without them we would not be in this favourable position.”

The company has also invested in a deburring machine.

Currently the company operates from Actavia Park, Gauteng in two factories, both approximately 450m², and it employs 12 staff.

For further details contact FMG Steel on TEL: 082 459 3604 or visit www.fmgsteel.co.za