More and more services are now offering the various options for cutting as part of their value-added services. But where is cutting headed in the years to come?The future of cutting will inevitably feature more technology. Will it also feature fewer people?
When it comes to cutting metal, many observers believe the inability to find skilled labor is the largest challenge facing the industry.
Hank White, laser product manager, Mazak Optonics Corp., Elgin, Ill., notes there are not a lot of people out there who want to do factory jobs. And many of the ones who are interested and capable are closing in on retirement.
“Now the biggest challenge is just finding the people, so the big push is for automation, better, smarter software to take the place of those people who aren’t there. We have less people going in and more product going out. You have to find a way to fill those product needs for people,” he said.
“What immediately comes to mind is personnel and training,” says Kris Scherm, manual plasma business and product director, ESAB, Denton, Texas. “And how to integrate a plasma cutter or a cutting operation into your existing workflow, whether it’s manual, semi-automated or fully automated, which ultimately leads to operational excellence. This challenge presents a tremendous opportunity to upskill either your workforce or upskill your actual units that are doing that cutting process.”
“The cutting industry is dealing with several critical challenges,” Grant Fergusson, TruLaser flatbed laser cutting product manager, TRUMPF Inc., Farmington, Conn., adds. “First and foremost, lead times and supply chain disruptions are putting huge pressure on manufacturers to deliver faster while keeping their costs in check. Customers are relying heavily on skilled operators and the ongoing labor shortage makes it difficult for them to find and retain qualified workers. This is pushing up demand for machines that are much easier to operate and reducing reliance on specialized expertise.”
Additionally, Fergusson says, laser cutting technology is becoming more attractive due to its durability, lower maintenance needs and minimal consumables compared to the traditional hard tooling or milling. With the laser, you have greater flexibility to cut different parts than you would with hard tooling where you might need to have a special tool made for you to fulfill the needs of a job. With the laser all you need to change is a program and you can easily create many different programs. Then, companies can streamline their production in a user-friendly way with an efficient machine and a strong supply chain, so they’ll have a competitive advantage in this evolving landscape.
Furthermore, Mark Trimper, regional manager, Hypertherm, OMAX division, Hanover, N.H., states the challenge is metal service centers today are being asked by their clients to produce a more finished product and what that means is having more capabilities at the metal service center.
Moreover, environmental and sustainability concerns are reshaping the metal processing industry. Don Kemper, president, Flex Machine Tools, Wapakoneta, Ohio, says high energy consumption remains an issue, with energy-intensive processes such as laser cutting and plasma cutting driving up operational costs and carbon footprints. Waste generation, particularly from scrap materials and byproducts, poses an environmental challenge, as inefficient recycling or disposal methods erode profitability and increase ecological impact.
“There’s pressure to adopt eco-friendly practices, Flex Machine Tools waterjets with closed-loop EBBCO systems and garnet recycling services, as well as FlexCNC large-format vertical machining centers utilizing efficient tooling, chip conveyors and coolant recycling services, will provide environmental and sustainable solutions toward this goal. This shift isn’t just about meeting mandates; it’s strategic positioning, as customers, investors and governments demand transparency and accountability. Forward-thinking companies are already pivoting toward renewable energy integration and advanced material recovery techniques, but the transition requires balancing capital investment with operational realities,” he adds.
Kyle Bukowski, team leader for product management, Messer Cutting Systems, Menomonee Falls, Wis., says sustainability and environmental issues are inherent to the process. The thermal cutting industry yields byproducts mainly in the form of dust or gases or vapors from the actual processing of the materials. “We have to be conscious of that discharge from our processes and of the environment so as an OEM or as a manufacturer, we’re working with air pollution control companies to provide filtering systems like dust collectors that attach to our equipment to keep the working environment for the end user as good as it can.”
Then, the end user also has a responsibility there to maintain a healthy working environment for their employees. If they’re working with outdated equipment that may not be working at the right efficiency, there’s a good chance they need to address something on their side as far as bringing in their pollution control like dust collection or filtration systems and maintenance of those systems to keep them working properly and efficiently, he says.
Likewise, Steve Zlotnicki, global product manager, cutting systems, ESAB, Denton, Texas, says environmental and sustainability is a common thread throughout the industry, with everyone trying to reduce carbon footprints and power usage. In the cutting space, the biggest use of power is laser systems, he says. Plasma systems also use a lot of power. People are going to be pushed to reduce their power usage, which is a big chunk of it in the case of some customers. As far as carbon emissions, the oxy-fuel cutting process is in focus right now because of the development of hydrogen cutting.
“When you’re cutting with an oxy-fuel process, you’re typically using natural gas or propane and when you burn those, your flame is generating carbon dioxide as one of the byproducts of that flame. When you burn hydrogen gas, the burning of hydrogen produces water vapor so there’s a significant incentive for someone who’s using a lot of propane or natural gas for cutting operations to switch over to use hydrogen as far as the incentives for reducing carbon output or carbon footprint; however, the problem is the cost right now,” he notes.
Next, there are common errors or inefficiencies in the cutting processes that need to be minimized. Kemper says in metals processing these often stem from a range of issues, including misalignment, excessive tool wear and material waste or scrap generation, particularly when using vertical machining centers and waterjets. These problems frequently arise due to improper setup or oversight, or the reliance on outdated equipment that no longer meets the part-tolerance requirements. A regular maintenance schedule can extend tool and equipment lifespan, while strategic upgrades or replacements of vertical machining centers and waterjets ensure alignment with current industry benchmarks.
“Integrating automation technologies can significantly reduce human-induced variability, while enhancing throughput and consistency. Equally critical is comprehensive operator training, which equips personnel with the skills to optimize processes, minimize waste and adapt to advanced systems like FlexCNC large-format vertical machining centers and Flex Machine Tools waterjets, while driving operational excellence and cost efficiency,” he remarks.
Chris Phillip, marketing manager, AKS Cutting Systems, Cleveland, says the biggest error in cutting is allowing engineers to over specify and to allow people to say, “‘I need this because this is what I always get.’” They don’t need it. You have to look at what the part is for. The base plate for a telephone pole doesn’t need to be made as well as a stint for a heart. It’s just that simple.
Another issue is not knowing the life of your cutting tools. “In my world, it’s the consumables and the plasma torch, the electrode in particular. I still have seen maybe up to $10,000 of wasted stuff because people don’t know the life of their cutting tools and that applies to bandsaw blades, that applies to discs and lasers, that applies to milling equipment. A lot of operators are undertrained on how to measure the total life and durable life of their tooling,” he explains.
Moreover, Fergusson states one method manufacturers might not be aware of to overcome a common inefficiency is using gas mixing technology, which gives the operators more bandwidth. The tolerance for potential error also becomes less and it makes the cutting process more forgiving. Adopting more gas mixing will allow the operators to become more efficient because they have a more forgiving parameter to work with.
Another inefficiency, according to Fergusson, is caused when steel service centers use plasma to create bevels in parts. New laser technology, which allows machines to automatically create bevels on both the upper and lower edges of a part during the cutting process, results in faster processing speeds at certain thicknesses which reduces production time, eliminates the need for secondary operations and increases efficiency through a larger number of parts produced per shift.
However, a lot of the time, White says, there’s not a whole lot of inefficiencies in the laser cut process itself. The issue seen in the industry is that the cutting process is now so fast it’s bottlenecking the rest of the processes down the line. There’s no way to organize those parts, keeping them flowing efficiently to the press brake, keeping them flowing efficiently to the paint line or to the welding area. That is where they’re backing up. Again, things such as automation help alleviate that as it organizes everything, he adds.
“Now, if you really want to get into efficiency on the laser machine as far as the cutting process goes, I would say it’s software related, being able to integrate with your ERP, order processing and being able to efficiently organize those jobs, parts and materials so they pull through the machine and get to the next process more efficiently,” he says.
Next, regulatory changes will also be shaping the metals space in the future. According to Kemper, over the next decade regulatory guidelines are expected to pivot sharply toward environmental sustainability, increased worker safety and greater supply chain transparency, reshaping the landscape for metal processing. Anticipated tightening of emissions standards will likely accelerate the shift to eco-conscious solutions, such as high-efficiency laser systems and waterjet technologies engineered for minimal waste and energy use, aligning compliance with operational savings.
On the safety front, tougher occupational standards are likely to cause a surge in automation adoption and AI-powered monitoring systems, reducing human exposure to risk while enhancing precision and oversight. “Evolving trade policies and stricter material sourcing mandates could impact global metal supply chains, compelling manufacturers to pivot toward localized production models and robust recycling programs. These moves not only ensure regulatory alignment but also bolster cost predictability in a volatile market. For industry players, this regulatory evolution isn’t just a hurdle, it’s a strategic driver of innovation and resilience,” he adds.
Zlotnicki believes the regulatory landscape in the U.S. is probably going to become less onerous and allow people to operate with lower costs and maybe bring down the costs of fabrication a little bit. On the other hand, tariffs may cause a lot of cost increases in the short term.
“Regulatory comments come all the way down to the sourcing of the raw materials in the steel industry. On the production side and within our company, we work with a lot of different vendors from purchase components to manufacturers to the machines that we sell to customers. The customer is also facing challenges on the sourcing of that material side,” Bukowski says.
“Any time regular regulation increases, generally price increases with that and availability becomes more challenging. Let’s say it becomes harder to get the raw materials because of regulation to produce steel, the price of steel is going to go up and the demand for steel is going to be affected by that. For us it’s on the component side of the machinery. If there’s imported products coming from other regions like Europe, we get a part from Europe but if tariffs or logistics or shipping and things like that come into play, that will affect our ability to purchase those components and then resell them with our products,” he adds.
What are some technological innovations that will affect the cutting industry in the near future? Bukowski says it will be automation. The cutting processes themselves are working well. The industry is more so focused on that initial problem of labor and or efficiency, trying to become more efficient in their practices. “Our customers are asking for solutions to be able to help them load their machinery with plate, unload the parts from their machinery and help facilitate operator-less manufacturing. From our side, we see automation as sort of the future of the cutting industry.”
AI and machine learning are also set to revolutionize cutting operations by improving automation efficiency and precision. “In the next five years, AI will play a central role in optimizing manufacturing processes, helping companies increase productivity while aiding operators to be better at their jobs by being proactive,” Fergusson adds.
Moreover, White says AI can do more without an operator and reduce the amount of cutting issues. Right now it’s easier on a fiber laser to produce parts because the process is simplified. There’s less to go wrong but it still requires in some applications a more advanced or experienced operator to make decisions, to fix issues either proactively or reactively. The next step is machines that are proactive and reactive to situations and take the operator kind of out of the equation so what that does is it improves productivity. It removes the potential for cutting bad parts and material so every time you cut a part that’s bad, you not only lose the part that costs you money now you have to reprogram it, resend it back through your system.
“True AI should be able to go through your entire work set and look at all of your production, look at all of your machines and capabilities and give you a very dynamic workflow that can change at any point throughout the day or the week and always yield the best results with the minimal amount of human intervention,” he states.
Similarly, by taking advantage of AI, Trimper says, companies can continuously do a better job of training operators so they know how to use the equipment safely and be more of an expert on the equipment. Then, the efficiency all around is going to be there.
Kemper says, the integration of artificial intelligence and machine learning is set to redefine the cutting industry, ushering in a new era of operational excellence marked by optimized cutting paths, minimized waste and precision. AI-driven systems are evolving to deliver real-time adaptability, dynamically adjusting to variables such as material characteristics, machine wear patterns and ambient conditions, ensuring quality across every cut.
“Meanwhile, predictive maintenance, fueled by machine learning algorithms, is poised to transform equipment management by preempting failures, reducing downtime and prolonging the lifespan of critical machinery. The synergy of automated process monitoring and adaptive control technologies will allow for unprecedented gains in efficiency, driving down labor costs while accelerating production throughput. These advancements will position metal processors to thrive in an increasingly demanding market,” he adds.
All in all, operators should be focusing on several items to prepare for future changes. According to Fergusson, operators should position themselves as technological leaders, actively guiding their management toward innovation by staying informed and embracing new advancements. They should become key drivers of their company’s growth, adaptability and competitive edge. Also, operators must continuously refine their skills, embrace new techniques and push for greater efficiency. They should avoid complacency, stay proactive, experiment and maximize the potential of cutting technology. “To be a real expert, you must observe, question, hypothesize, experiment, analyze and conclude. Most importantly, you must communicate with your management to make future changes,” he says.
Accordingly, Trimper says the industry will see more advanced technology do more complete work for the end customer. The product and technology being sold is getting more and more complicated all the time, meaning the operators need to be able to handle a more complicated piece of equipment without injuring themselves, being efficient in the cuts and protecting the equipment itself. These are large investments and they’re becoming larger investments. How do you keep that machine up and running and keep it as a profitable investment to use for an end customer?
“If I were talking to a customer today, I would tell them to focus on developing your own business and making it as lean and cost efficient as possible because competition is going to continue to be fierce in the future especially in the shrinking market. If trends continue over the next couple of years and business gets tighter, only the best will survive,” Zlotnicki concludes.
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Energy consumption and waste reduction will be key drivers of advancements in years to come, says Flex Machine Tools’ Don Kemper. (Photo courtesy Flex Machine Tools)