TRUMPF has introduced an advanced laser-based solution aimed at lowering manufacturing costs in hot forming applications. The technology enables manufacturers to reduce component costs by up to 20 per cent when processing hot-formed parts used in safety-critical automotive structures.
The newly developed solution responds to growing industry challenges such as rising energy prices, high cutting gas costs, and production interruptions. By integrating a redesigned cutting nozzle, a new generation of fibre lasers, and established beam shaping technology, the company has enhanced efficiency and process stability in laser cutting operations.
Speaking on the development, Ralf Kohllöffel, responsible for product management of 3D systems at TRUMPF, noted that the combined approach allows manufacturers to achieve consistent, high-quality results while improving operational efficiency. The technology is being showcased at INTECH, the company’s in-house exhibition in Ditzingen.
At the core of the solution is a newly engineered cutting nozzle designed to increase the distance between the nozzle and the sheet surface by several millimetres. This enhancement significantly reduces the risk of collisions during the cutting process, a common issue that previously caused equipment damage, inconsistent cutting quality, and unplanned downtime.
Testing has demonstrated that the new nozzle can operate continuously for more than three months without replacement, compared to the significantly shorter lifespan of earlier nozzle designs. The improved system also ensures stable cutting performance even under variable production conditions or less precise programming. This is particularly beneficial when using compressed air as a cutting gas.
A major advantage of the innovation lies in its ability to replace nitrogen with compressed air, resulting in cutting gas cost savings of up to 75 per cent. While compressed air has traditionally been viewed as less reliable for high-performance applications, the integration of the X-Blast 2.0 nozzle with BrightLine Speed beam shaping technology enables consistent operation even in continuous, high-output manufacturing environments.
BrightLine Speed allows higher cutting speeds at lower laser power levels, enabling users to achieve faster processing with reduced energy consumption. The new generation of fibre lasers further enhances efficiency by lowering overall power usage, reducing energy consumption per component.
TRUMPF is a global technology leader in machine tools and industrial laser systems. The company provides manufacturing solutions that support digital integration through software, platforms, and consulting services. Recognized as a market leader in sheet metal processing and laser technology, TRUMPF reported sales of €4.3 billion in 2024/25 and employs over 18,000 people worldwide. With approximately 90 subsidiaries, the group maintains a strong presence across Europe, North America, South America, and Asia, supported by production facilities in multiple countries.
