In the duct shop world, many HVAC sheet metal contractor customers sought a less bulky machine footprint and structure; an ability to address smaller, more diverse cutting lots; a desire to feed the cutting table from coiled metal; and quicker access to the cut pieces for part removal to secondary operations and the affixing of labels. The Lockformer Vulcan Fiber Laser Cutting System was developed with those customer design parameters in mind while still assuring that the focused laser beam itself would always be shrouded, contained, or disabled, setting the standard for safety with its accession number and coveted Class 1 safety rating from the Food and Drug Administration (FDA).
What is a Class 1 Laser?
According to the FDA (source):
The FDA recognizes four major hazard classes (I to IV) of lasers, including three subclasses (IIa, IIIa, and IIIb). The higher the class, the more powerful the laser is and the greater the potential to pose serious injury if used improperly. The labeling for Classes 1-4 must include a warning symbol that states the class and the output power of the product. Roughly equivalent IEC classes are included for products labeled under the classification system of the International Electrotechnical Commission.
| Class FDA | Class IEC | Laser Product Hazard | Product Examples |
|---|---|---|---|
| I | 1, 1M | Considered non-hazardous. Hazard increases if viewed with optical aids, including magnifiers, binoculars, or telescopes. |
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| IIa, II | 2, 2M | Hazard increases when viewed directly for long periods of time. Hazard increases if viewed with optical aids. |
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| IIIa | 3R | Depending on power and beam area, can be momentarily hazardous when directly viewed or when staring directly at the beam with an unaided eye. Risk of injury increases when viewed with optical aids. |
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| IIIb | 3B | Immediate skin hazard from direct beam and immediate eye hazard when viewed directly. |
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| IV | 4 | Immediate skin hazard and eye hazard from exposure to either the direct or reflected beam; may also present a fire hazard. |
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While containing a Class 4 laser source, the Vulcan® Fiber Laser Cutting System's full encapsulation of the laser beam within the shroud and the related interlocks allows the FDA to classify the machine as a Class 1 laser.
Reflecting the highest safety and quality standards, the FDA’s thorough evaluation process includes meticulous design and manufacturing process reviews, extensive performance testing, and strict compliance with laser safety standards. This leads to the assignment of an FDA accession number and a Class 1 safety rating, underscoring the system’s reliability, effectiveness, and adherence to rigorous safety protocols.
To ensure that the machine is delivering a safe product following FDA guidelines, Mestek Machinery hired a well-known and experienced consulting firm, Rockwell Laser Institute (RLI), to assist in obtaining the FDA accession number displayed on every Fiber Laser cutting system. An FDA accession number facilitates communication about specific reports because all parties can use the accession number to identify the document being discussed.
After many months of consulting on numerous designs for features of the safety shroud, considerations of material, software, table and movement conditions that could tear, break or damage the integrity and purposes of the shroud during operation, set up or maintenance; accidental and purposeful defeating of the integrity and purposes of the shroud; brain-storming on foreseeable misuses of the cutting system and other safety modifications, Mestek Machinery applied for and received its FDA accession number on February 18, 2016. In full, the process to receive the accession number lasted about two and a half years.
Of course, Mestek Machinery was also able to draw upon more than 35 years of experience in manufacturing and servicing plasma, knife-edge and water-jet systems in the sheet metal forming and fabricating industry during this process.
Safety Features of the Vulcan Fiber Laser Cutting System
The Lockformer Vulcan® Fiber Laser Cutting System features a Class 1 fiber laser with open architecture design which not only allows for easy integration into existing workflows and customization according to specific production needs but also promotes adaptability for future technological advancements. And the patented shroud design in the system further elevates its operational safety and cutting precision, ensuring high-quality results while mitigating hazardous risks. These innovative features collectively simplify maintenance procedures, significantly reducing downtime and bolstering continuous operational efficiency.
Comprehensive Laser Safety
Lockformer’s patented shroud design of the Fiber Laser Cutting System contributes to both performance and safety during the cutting process. The design enhances operator safety by containing potentially hazardous materials and preventing them from escaping into the surrounding environment. Additionally, by effectively managing airflow and debris, the shroud minimizes the risk of contamination and ensures consistent cutting quality.
Minimized Exhaust Emissions
The Fiber Laser Cutting System operates completely on compressed air with minimal to zero exhaust. The use of compressed air significantly reduces harmful emissions that are often associated with conventional cutting methods. By eliminating the need for gases or other chemicals, this system presents an environmentally responsible solution, ensuring a cleaner and safer working environment. This aspect is particularly vital in today’s industry, where environmental impact and worker safety are paramount. Chemicals taken out.
Ease of Maintenance and Serviceability
Open architecture simplifies access to internal components, making maintenance and servicing tasks more straightforward and efficient. This accessibility reduces downtime for maintenance, minimizing disruptions to production schedules, and ensuring continuous operation. Similarly, the design of the patented shroud facilitates easy cleaning and upkeep, further contributing to the system’s overall reliability and longevity.
Direct Access
The open architecture of the Fiber Laser Cutting System allows workers to have direct access to the cutting table, eliminating the need for a pallet shuttle system. This enables operators to efficiently remove parts directly from the table, streamlining the production process, and reducing the reliance on additional equipment for part retrieval.
Why Sheet Metal Laser Cutting Safety Matters
As exposure to a focused laser beam can be hazardous to human tissue – especially the eyes, most laser cutting systems use a full enclosure or structure that surrounds the entire area of the cutting table to address safe operation. However, this design was developed for large manufacturers with high volume, repetitive cutting needs and shops that are capable of supporting the floor space, intermittent table access, and expense of sheet feeding typical of a fully enclosed laser cutting structure. The innovations made to the Lockformer Vulcan Fiber Laser allowed for the same safety benefits with a smaller footprint.
The Vulcan Fiber Laser's protective shroud covers the torch assembly to fully capture the laser beam. By enclosing only the laser torch head adjacent to and above the cutting area, the fiber laser takes up less space and allows the operator to quickly load/unload parts and coil feed the table. Combining a Class 1 fiber laser with a patented shroud design ensures maximum safety for operators and surrounding personnel by eliminating any hazards within a controlled environment. This configuration minimizes the risk of exposure to hazards, promoting a secure work environment, and compliance with safety regulations. The Class 1 fiber laser is a low-powered device that is considered safe from all potential hazards during normal use.
In addition, Mestek Machinery provides a comprehensive Operation/Safety Manual, IPG Operation/Safety Manual and a copy of the most recent LIA – Laser Safety Guide. Upon commissioning and start up, Mestek Machinery provides 5 days of operation and safety training. Although compliance with the rules and regulations of OSHA for worker safety are to be assured by the acts of the company using the machinery, those standards were also given due consideration in our design and warning choices.