Cutting Windows for Different Metals: Stainless, Carbon Steel, Aluminum and Brass with 800W & 1200W Handheld Fiber Lasers
For handheld fiber laser cutting, the real question is not just “can it cut this metal?”, but “how fast can it cut this thickness with stable quality?”. This article uses real test data from GWEIKE 800 W and 1200 W handheld fiber lasers to show the cutting window for four common metals: stainless steel, carbon steel, aluminum and brass (1–4 mm).
What Is a “Cutting Window” for Handheld Fiber Lasers?
In production, operators usually keep the gas type, gas pressure and laser pulse parameters within a narrow range and only adjust cutting speed based on material and thickness.
- fully penetrates the sheet
- keeps slag and burrs under control
- avoids excessive heat affected zone (HAZ)
Test Setup & Common Parameters
All data below comes from handheld fiber laser tests under consistent conditions.
- Laser power: 800 W / 1200 W
- Gas: Nitrogen 6–8 bar
- PWM duty cycle: 100%
- Scanning frequency: 1000 Hz
- Peak power: 65–95%
- PWM duty cycle: 100 %
- PWM / scanning frequency: 1000 Hz
- Scan width: 5 mm
Stainless Steel Cutting Window (1–4mm)
| Thickness (mm) | 1200 W | 800 W | ||
|---|---|---|---|---|
| Speed (mm/s) | Peak power (%) | Speed (mm/s) | Peak power (%) | |
| 1.0 | 18 | 65 | 12 | 75 |
| 2.0 | 12 | 75 | 8 | 85 |
| 3.0 | 8 | 85 | 6 | 95 |
| 4.0 | 6 | 95 | – | – |
Key observations:
- 1200 W is ~50% faster at 1–2mm
- Only 1200W has a stable window at 4mm
- At 4 mm, only 1200 W keeps a stable window (6 mm/s). 800 W is close to its practical limit.
Carbon Steel Cutting Window (1–4mm)
Carbon steel is generally easier to cut than stainless steel. With nitrogen, we get clean edges without oxidation. The speed trends are similar to stainless:
| Thickness (mm) | 1200W | 800W | ||
|---|---|---|---|---|
| Speed (mm/s) | Peak power (%) | Speed (mm/s) | Peak power (%) | |
| 1.0 | 18 | 65 | 12 | 75 |
| 2.0 | 12 | 75 | 8 | 85 |
| 3.0 | 8 | 85 | 6 | 95 |
| 4.0 | 6 | 95 | – | – |
In practice, if a workshop occasionally needs oxidized edges for easy painting, oxygen assist can further increase the speed, but that is a different process window. Here we focus on nitrogen cutting where edge quality and minimal post-processing are the priority.
Aluminum Cutting Window (1–4mm)
Aluminum is reflective and demands more attention to safety and optical protection, but with proper anti-reflection design the cutting window is very similar to steel in this thickness range.
| Thickness (mm) | 1200 W | 800 W | ||
|---|---|---|---|---|
| Speed | Peak power | Speed | Peak power | |
| 1.0 | 18 | 65 | 12 | 75 |
| 2.0 | 12 | 75 | 8 | 85 |
| 3.0 | 8 | 85 | 6 | 95 |
| 4.0 | 6 | 95 | – | – |
Practical notes for aluminum:
- Always make sure the handheld system includes a proper back-reflection isolator.
- Use clean, oil-free nitrogen to avoid porosity and surface stains.
- For regular jobs in 3–4 mm aluminum, 1200 W offers a much more comfortable working window.
Brass Cutting Window (1–2mm)
Brass has even higher reflectivity than aluminum. In our tests we focused on thin sheets up to 2.0 mm.
| Thickness (mm) | 1200W | 800W | ||
|---|---|---|---|---|
| Speed | Peak power | Speed | Peak power | |
| 1.0 | 12 | 75 | 8 | 95 |
| 2.0 | 8 | 95 | – | – |
For brass, we recommend limiting routine handheld cutting to 1–2 mm, using 1200 W where possible and always following the safety recommendations on reflective materials. If thicker brass must be processed frequently, a higher-power cutting station is a better choice.
800W vs 1200W Productivity
Using the data above, we can compare how much speed gain 1200 W provides in typical jobs:
| Metal & thickness | 800W | 1200W | Increase |
|---|---|---|---|
| Stainless steel 1.0 mm | 12 | 18 | +50% |
| Stainless steel 2.0 mm | 8 | 12 | +50% |
| Stainless steel 3.0 mm | 6 | 8 | +33% |
| Aluminum 3.0 mm | 6 | 8 | +33% |
| Brass 1.0 mm | 8 | 12 | +50% |
For workshops that mainly handle 1–2 mm repair and modification work, an 800 W handheld system is usually sufficient. If 3–4 mm stainless or aluminum plates are processed regularly, or if shorter cycle time is critical, the 1200 W option provides a clear productivity advantage and a wider process window.
How to Use These Curves in Your Workshop
To turn the cutting windows into a daily workflow, we recommend the following steps:
- Choose the metal and thickness you need to cut and find the recommended speed for your laser power.
- Set nitrogen pressure to 6–8 bar and use the corresponding peak power from the tables.
- Cut a short test line (100–200 mm) and check penetration, slag and color.
- If not fully cut, reduce speed by 10–15 % or slightly increase peak power.
- If there is excessive burning or wide HAZ, increase speed slightly or reduce power.
- If there is too much slag, check focus position and increase gas pressure within the safe range.
Over time, your team can build its own parameter cards based on these starting points, tailored to your material suppliers and real part geometries.
Next Step: Test Your Own Parts with GWEIKE Handheld Systems
The cutting windows above are based on straight-line cuts on standard plates. Real parts may have tighter contours, corner slowing and special surface requirements. If you want to verify the performance on your own parts, our application team can help:
- Free sample cutting tests for typical workpieces
- Application reports with photos and recommended settings
- On-site training for handheld cutting, welding and cleaning
Contact GWEIKE to schedule a demo or request the full handheld cutting parameter sheet in PDF format.
