Laser Equipment Power Consumption Reference
Complete guide to energy usage and electricity costs
Fiber Laser Power Consumption
| Laser Power | Laser Module | Chiller | Exhaust | Controls | Total System |
|---|---|---|---|---|---|
| 1 kW | 1 kW | 1.5 kW | 0.5 kW | 0.3 kW | 3-4 kW |
| 2 kW | 2 kW | 2.0 kW | 0.7 kW | 0.3 kW | 5-6 kW |
| 3 kW | 3 kW | 2.5 kW | 0.8 kW | 0.5 kW | 7-8 kW |
| 4 kW | 4 kW | 3.0 kW | 1.0 kW | 0.5 kW | 9-10 kW |
| 6 kW | 6 kW | 3.5 kW | 1.2 kW | 0.5 kW | 11-13 kW |
| 8 kW | 8 kW | 4.0 kW | 1.5 kW | 0.5 kW | 14-16 kW |
| 12 kW | 12 kW | 5.0 kW | 2.0 kW | 0.8 kW | 20-22 kW |
| 15 kW | 15 kW | 6.0 kW | 2.5 kW | 1.0 kW | 25-28 kW |
Fiber lasers are highly efficient: 25-30% wall-plug efficiency. Actual power varies by brand and configuration.
CO2 Laser Power Consumption
| Laser Power | Laser Tube | RF Supply | Chiller | Exhaust | Total System |
|---|---|---|---|---|---|
| 1 kW | 1 kW | 4 kW | 3 kW | 1 kW | 10-12 kW |
| 2 kW | 2 kW | 8 kW | 4 kW | 1.5 kW | 16-20 kW |
| 3 kW | 3 kW | 12 kW | 5 kW | 2.0 kW | 23-28 kW |
| 4 kW | 4 kW | 16 kW | 6 kW | 2.5 kW | 30-35 kW |
| 6 kW | 6 kW | 24 kW | 8 kW | 3.0 kW | 42-50 kW |
CO2 lasers are less efficient: 8-12% wall-plug efficiency. They consume 3-4x more power than equivalent fiber lasers.
Operating Cost Comparison
Annual electricity costs at different usage levels
6kW Fiber Laser
3kW CO2 Laser
5-Year Energy Savings: A 6kW fiber laser saves $10k-25k in electricity costs compared to a 3kW CO2 laser over 5 years (40 hrs/week operation). This often justifies the higher initial equipment cost.
Understanding Power Consumption
Peak vs. Average Power
The power ratings shown are peak consumption during cutting. Actual average power depends on duty cycle:
- Continuous cutting: 80-90% of peak power
- Typical job shop: 60-70% of peak (includes setup, loading, programming)
- Prototype/low volume: 40-50% of peak
Electrical Service Requirements
Ensure your facility has adequate electrical capacity:
- 1-3kW fiber: 208V 3-phase, 30-50A service
- 4-8kW fiber: 208V or 480V 3-phase, 60-100A service
- 10-15kW fiber: 480V 3-phase, 100-150A service
- CO2 lasers: Typically require 480V 3-phase, add 50% capacity for RF supply
Chiller Power Consumption
Chillers are the second-largest power consumer. Factors affecting chiller power:
- Ambient temperature: +20% power in summer vs. winter
- Chiller efficiency: Modern scroll compressors use 30% less than older models
- Maintenance: Dirty condensers increase power by 15-25%
Standby Power
Lasers consume power even when idle:
- Fiber laser standby: 1-2 kW (chiller, controls, laser module warmup)
- CO2 laser standby: 3-5 kW (higher due to gas circulation)
- Tip: Turn off equipment during extended breaks (lunch, overnight) to save 10-20% on energy
Energy Efficiency Optimization
1. Optimize Cutting Parameters
Running at 80-90% of maximum speed often uses 20-30% less power than maximum speed while maintaining acceptable cut quality. Over-powering (using 6kW when 4kW suffices) wastes energy.
2. Maintain Chiller Efficiency
Clean condenser coils quarterly, check refrigerant levels annually. A well-maintained chiller uses 15-25% less power. Consider upgrading to variable-speed compressor chillers for 30% energy savings.
3. Batch Similar Jobs
Minimize start/stop cycles. Each laser startup consumes 2-5 minutes of full power for warmup. Batching jobs saves 10-15% on energy costs compared to frequent on/off cycling.
4. Consider Time-of-Use Rates
Many utilities offer lower rates during off-peak hours (nights, weekends). Shifting production to off-peak can save 30-50% on electricity costs. Check if your utility offers time-of-use pricing.
5. Monitor Power Factor
Poor power factor (<0.85) can result in utility penalties. Install power factor correction capacitors if needed. Most modern laser systems have good power factor (>0.90), but older CO2 lasers may need correction.