When it comes to precision metal fabrication, choosing the right laser cutting method can significantly impact both the quality and efficiency of your project. At Caltech Manufacturing, we specialize in both flat laser and tube laser cutting—each designed for specific applications and outcomes.
Understanding the difference between these two fabrication techniques can help engineers, project managers, and procurement teams make smarter, more cost-effective decisions.
What Is Flat Laser Cutting?
Flat laser cutting involves the use of a high-powered fiber laser to cut shapes out of flat sheet metal. At Caltech, we use a 4kW fiber flat laser with a shuttle table that enables high-speed, continuous cutting of various materials—including steel, stainless steel, aluminum, copper, and brass.
Best Uses for Flat Laser Cutting:
- Flat components for enclosures, brackets, or panels
- Complex geometries or detailed part designs
- Rapid prototyping and high-volume production
- Tight tolerance applications
- Clean, burr-free edges
Key Benefits:
- Extremely precise cuts, even on intricate shapes
- Works with a wide range of materials and thicknesses
- Fast production with minimal material waste
- Ideal for 2D parts that require further forming or assembly
What Is Tube Laser Cutting?
Tube laser cutting, on the other hand, is used specifically to cut cylindrical, square, or rectangular tubing. At Caltech Manufacturing, we operate a TRUMPF tube laser capable of processing tubing up to 4.25” in diameter. This method uses a rotary axis to rotate the tube during cutting, which allows for precise hole placement, notches, slots, and more.
Best Uses for Tube Laser Cutting:
- Structural components like frames, rails, and supports
- Perforated or slotted tubing
- Assemblies requiring precise joints or interlocking parts
- Decorative or architectural metalwork
- Projects that benefit from reduced welding or machining
Key Benefits:
- Creates complex geometries without secondary operations
- High repeatability and accuracy on long tubes
- Reduces need for fixtures and post-processing
- Supports automation and lean manufacturing goals
How to Choose: Flat Laser vs. Tube Laser?
| Criteria | Flat Laser Cutting | Tube Laser Cutting |
|---|---|---|
| Material Shape | Flat sheet metal | Round, square, or rectangular tubing |
| Part Geometry | 2D shapes | 3D tube features like holes, slots, and notches |
| Common Industries | Electronics, enclosures, equipment panels | Furniture, frames, structural components |
| Setup & Processing | Fast setup; minimal fixturing | Rotational cutting; more complex setup |
| Best For | Brackets, panels, mounting plates | Rails, chassis, custom tubing assemblies |
When a Project Uses Both
Many assemblies require both flat and tubular components. That’s why Caltech’s end-to-end capabilities—including bending, welding, and full assembly—make us a trusted partner across a wide range of industries. We can take your flat parts, your tubular frames, and everything in between and integrate them into finished subassemblies ready for market.
Final Thoughts
The choice between flat and tube laser comes down to part geometry, material form, and end-use application. Both processes offer exceptional precision and efficiency—but when paired with expert handling and assembly services, they become even more powerful.
At Caltech Manufacturing, we’ll help you evaluate which process—or combination of processes—is best suited for your needs. Whether you’re working on a one-off prototype or a large production run, our experienced team is ready to deliver high-quality results with speed and consistency.
Have a project in mind?
Contact us today to request a quote or explore our capabilities in more detail.