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Industrial Laser Maintenance for CO2 and Fiber Lasers

authorIcon By Jonathan Lee on January 15, 2025 topicIcon Industrial Lasers

Every minute your machine sits idle, it directly impacts your bottom line.

Output decreases, production bottlenecks occur, and production schedules fall behind.

According to Deloitte, poor maintenance habits can reduce production capacity by between 5% and 20%. It’s no wonder that industrial manufacturers lose an estimated $50 billion annually to unplanned downtime.

We know it can be tempting to keep lasers running full-tilt and put off maintenance for later — especially when you have a long list of other equipment needing repair or maintenance.

However, preventative laser machine maintenance is key to save money and maximize your output. As a bonus, you’ll increase the lifespan of your equipment, too.

In this article, you'll discover the essential maintenance items and preventative measures for the two most common types of laser: CO2 lasers and fiber lasers.

Table of Contents

CO2 Lasers Maintenance

While fiber lasers make up the overwhelming majority of new purchases, there are tens of thousands of CO2 laser cutting and marking machines remaining in operations across the country.

Some of the more common problems you may encounter in operation include:

Dirty Optics and Cutting Head Gaskets

Contamination on optics and gaskets can interfere with the laser beam, reducing cutting or marking efficiency. Dirt on gaskets can also be transferred to the lenses or cause debris to circulate, which can impact performance and increase malfunctions.

Damaged Beam Delivery

Over time, you may develop tiny holes in bellows that introduce debris in the beam path and can damage mirrors and lenses. Even if lenses aren’t damaged, the buildup can leave a film behind from the liquid nitrogen used for purging the bellows.

Contaminated Quartz Tubes

Quartz tubes should be clear. A contaminated laser tube often appears black or white (depending on the resonator). This can reduce resonator power and efficiency. In extreme cases, quartz pieces can break and get stuck inside the tube.

The culprit is often operators failing to change laser gas bottles at appropriate intervals. When CO2, helium, and nitrogen laser gas pressures fall below the manufacturer’s recommendation, you need to swap out the bottle for a new one. If you let it go too low, you’re damaging the resonator.

Gas Line Leaks

If it seems like you’re having to swap out bottles more frequently, you may have a gas line leak.

Cooling System Issues

Dirt, debris, and a poor chemical balance in the coolant water can corrode components or reduce cooling power. You sometimes see microbial growth in the chiller water as well. This can clog filters and diminish the lifespan of your machine.

Preventative Maintenance for CO2 Lasers

All of these problems can be avoided with regular inspections and proper maintenance.

Here are a few guidelines to reduce your risk:

  • Inspect and clean bellows, mirrors, and lenses regularly and replace any damaged components immediately.
  • Clean optics at least every three months or anytime you suspect diminished performance. Use filtered air to clean out any debris. Don’t let shop air into the system which may introduce contamination.
  • Monitor gas bottle pressure and replace it as recommended. Alarms can help you ensure they don’t fall below preset thresholds. You should also clear debris when you are changing bottles using purge valves to prevent contamination from entering the resonator.
  • Flush system water yearly. Replace chiller filters every six months.
  • Leak-test gas lines periodically or when you see sudden drop-offs.
  • Perform power tests and calibration to verify performance and detect any power loss.

Fiber Laser Maintenance

Fiber lasers have fewer moving parts than CO2 lasers, but that doesn’t mean they are completely maintenance-free. There can still be breakdowns requiring laser repair. Common concerns with fiber lasers include:

Dirt and Damage on Protective Lenses

Dirt and debris on the cover lens can “cook” the laser, causing the lens and performance to deteriorate. Dirt can also accumulate quickly if the air knife or air assist isn’t working efficiently.

Reflection from work surfaces or dirt can cause energy to be redirected into the laser head and interfere with laser engraving or marking. This can create overheating and lead to failure.

Laser Power Degradation

Over time, laser machine power may drop below optimal levels, affecting the cleaning or marking process. This is a slow, but normal process. If you see a sharp decrease in power in your marking or laser cutting machines, there’s likely an underlying issue that requires more immediate attention.

Cable Damage and Misalignment

Cables connecting laser components can wear out over time or snap, especially in installations with frequent motion, such as robotics. Vibration or movement can sometimes misalign components, especially in environments with heavy machinery.

Preventative Maintenance for Fiber Lasers

Preventative maintenance is critical for peak performance of fiber laser equipment, including:

  • Cleaning the protective lens at least weekly (or more frequently in dirty or dusty environments). Do not use an oil-based product as a cleaning solution. You need to be gentle with the lens.
  • Replace the protective lens at least once a year or sooner if you note degradation in performance.
  • Measure and track laser power regularly to catch any potential issues and avoid performance drops. Build a history to measure over time to help you know when it’s time for service.
  • Adjust the focus periodically to ensure alignment.
  • Keep spare cables and critical components on hand to minimize downtime. For example, replacement parts for a controller might take a week or two to get the parts you need, while replacing the head or source may take way more time, creating extremely costly repairs.

It’s a good idea to implement annual or twice-a-year professional inspections and evaluations of your laser system. Some newer models allow for remote diagnostics, making regular checks easier.

Don’t Skip on Preventative Maintenance

Regardless of the type of laser system you are operating, preventative maintenance is essential. You’ve invested in the equipment, and it’s a key part of your manufacturing process, so you need to keep it in good working condition.

The best advice? Train your technicians, create a formal maintenance schedule, and stick to it. Most inspections and regular maintenance tasks take only a few minutes. With a schedule, you can plan your downtime to limit disruption to your operations.

Along with a warranty, you might want to get high-quality professional laser service from your manufacturer or distributor at least once a year to go through everything from top to bottom. 

Consider investing in a maintenance package that includes annual or semi-annual inspections. The investment can save you a lot of trouble!

Jonathan Lee's picture

Jonathan Lee

With a background in microelectronics engineering, robotics, and high-voltage power distribution, Jonathan brings technical expertise to his role as Sales Manager at Laserax, specializing in optimization projects. His experience in designing and adapting automated systems drives innovative, reliable solutions that meet complex challenges and deliver measurable improvements.