AirCut Compressed Air Laser Cutting — Savings Instead of Nitrogen Costs

Compressed-air laser cutting —AirCut technology—is one of the simplest ways to reduce the cost per part in laser manufacturing. In many facilities, nitrogen—used as the assist gas—is one of the largest operating costs associated with fiber laser cutters. AirCut allows you to significantly reduce nitrogen consumption while maintaining a stable process and very good edge quality.

This isn’t just theory—one of STIGAL’s customers reduced costs by approximately 30,000 zł per month after implementing AirCut by switching from nitrogen to compressed air. The choice of assist gas is therefore not just a technical detail, but a real opportunity for cost optimization—especially when working with thin steel plates and in mass production.

What is AirCut?

AirCut is a compressed-air laser cutting technology developed by STIGAL. It uses air as a cost-effective assist gas—without compromising process stability or part quality. Nitrogen is often used in standard laser cutting: as an inert gas, it limits edge oxidation and produces a clean cut surface, but it generates high operating costs, especially during high-volume production.

Compressed air is an alternative—all you need is a properly selected compressor to supply gas for the process and reduce dependence on nitrogen supplies. With properly selected parameters, as in AirCut technology, very good quality results can be achieved; much depends on the grade and thickness of the steel plate, as well as the requirements for the finished part.

AirCut vs. Nitrogen — Key Differences

In practice, the most important difference is cost—assuming comparable technological quality and cutting speed.

In many industrial applications, the edge quality achieved with AirCut technology is fully adequate, which is why companies are increasingly choosing compressed air as their primary gas for mass production.

Why can air cutting reduce costs so significantly?

The greatest savings come from reducing nitrogen consumption—in many facilities, this is one of the most significant operating costs associated with laser cutting, especially for large, high-volume production runs and when machines operate for many hours. Companies can spend tens of thousands of zlotys a month on this gas, so switching to compressed air yields an immediate, significant benefit. The compressor prepares air to the required specifications, and the total cost of cutting with air is significantly lower than with nitrogen. In mass production, such savings directly translate into profit margins, the competitiveness of the product offering, and the payback period for the machine investment.

Sample Cost Estimate for Cutting

Below is a real-world comparison of the cost and time required to cut the same part ( 5 mm steel plate) using three different technologies. Here you can see why, for thin and medium-thickness steel plates, fiber laser cutting with air cutting (AIR CUT) is increasingly the preferred choice—it is several times faster and the least expensive per plate.

Sample data (part test for the boiler manufacturing industry, 5 mm steel plate). The actual cost depends on the part, material, process parameters, and utility prices.

The cost of laser cutting includes: the machine’s power consumption, the laser source, the laser cooler, the exhaust fan, the compressor, and the cost of gas for O2 CUT and N2 CUT technologies.

The cost of plasma cutting includes: the power consumption of the machine, the plasma power supply, the exhaust fan, and the compressor.

Sheet metal and 12 kW of power — the greatest potential for savings

AirCut technology is particularly advantageous when cutting thin steel plates—that’s where the combination of high cutting speed, good edge quality, and low gas costs yields the greatest economic benefit. The high power of the laser source isn’t limited to thick materials: with the right configuration, steel plate about 3 mm thick can be cut at speeds of up to 25 m/min—using compressed air.

As a result, the facility simultaneously:

• It cuts very quickly,
• reduces the cost of auxiliary gas,
• performs more operations per unit of time,
• reduces the cost of a single item,
• makes better use of the machine’s potential,
• reduces time for order fulfillment.

AirCut is not, however, a solution limited to very thin steel plates. With a 12-kW laser, it is possible to cut with air up to about 10 mm—depending on the material, quality requirements, and process parameters. For many facilities, this means greater flexibility: nitrogen is no longer the default choice for every part, and higher laser power becomes a tool for increasing productivity—not just for cutting thicker materials.

It is worth noting that compressed-air cutting is not limited solely to thinner steel plates and lower-power sources. Effective air cutting is also possible with higher-power fiber lasers. For 20-kW lasers, air can be used to cut steel plates up to about 20 mm thick, while for 30-kW lasers, this range can extend to as much as about 30 mm. This means that air is becoming an increasingly versatile process gas—not only in the production of thin parts, but also in applications where productivity, reduced costs for process gases, and the ability to work with thicker materials are key.

Edge Quality and Cutting Tests

The most common concern with air cutting is edge quality. In practice, thanks to AirCut technology, the edge quality is very good—aesthetically pleasing, smooth, and fully acceptable for subsequent processing steps, such as welding, bending, or assembly. The edge may be slightly darker and more matte than after nitrogen cutting, but this does not indicate inferior technical quality.

Nitrogen remains the best choice when a maximally bright, unoxidized edge is required—for example, for certain stainless steel or aluminium parts, or components with high aesthetic requirements. That’s why AirCut doesn’t have to replace nitrogen entirely: use nitrogen where it’s truly needed, and use AirCut where it allows you to cut more cost-effectively, quickly, and with very high quality.

Every facility has different requirements, which is why the best method of evaluation is to conduct cutting tests on actual workpieces. These tests allow you to evaluate edge quality, cutting speed, the actual cost of producing the part, and the impact on subsequent manufacturing operations—the decision is then based on the specific part and material, rather than on assumptions.

When is AirCut particularly cost-effective?

AirCut is most effective when a plant wants to reduce the unit cost of a part without compromising production efficiency. It delivers the best results when:

• mass production and high monthly nitrogen consumption,
• cutting thin and medium-gauge steel plates,
• technical and design details, as well as components for further processing,
• production where high cutting speed is essential,
• shift work,
• in an effort to reduce dependence on gas supplies.

The cost-effectiveness of AirCut can be calculated very precisely—simply compare the cost of cutting the same part with nitrogen and with air, as well as the cutting speed, edge quality, and any necessary post-processing. If the part meets quality requirements after being cut with air, the economic difference can be very significant—such as the aforementioned ~30,000 PLN per month for one of STIGAL’s customers.

Summary — AirCut: A Realistic Path to More Affordable Laser Cutting

AirCut compressed-air laser cutting is a viable path to lower production costs—especially in facilities that cut large volumes of thin and medium-gauge steel plates. Reducing nitrogen consumption lowers the unit cost per part, increases profitability, and allows for better utilization of the fiber laser cutter’s potential. With a 12 kW laser, AirCut can cut steel plates up to approximately 10 mm thick, and thin sheet metal (e.g., 3 mm) at speeds of up to 25 m/min, depending on process conditions.

Frequently Asked Questions — AirCut