Over the past few months we have been working hard to develop our in-house capability to efficiently take complex artwork from artists and architects intended for laser cut panels, and convert to analysis models that can be quickly assessed for structural compliance to the latest design codes.
See below information and images relating to the process. If you have a piece of artwork you want laser cut into mild steel, stainless steel, or weathering steel plate, and need to know if the arrangement proposed is structurally sound and will not distort, we can help.
Laser cut panels and their use in architecture
A laser-cut panel is a meticulously crafted architectural element created through the precision cutting of materials using laser technology. These panels are typically made from various materials such as metal, wood, acrylic, or even stone. The process involves using a focused laser beam to precisely cut intricate patterns, designs, or perforations into the chosen material. Laser-cut panels are highly versatile and can be used in numerous architectural applications. They offer both functional and aesthetic benefits to buildings. Functionally, laser-cut panels can serve as sunscreens, privacy screens, or even structural components. Aesthetically, they add depth, texture, and visual interest to facades, interior spaces, partitions, and other architectural elements. By harnessing the power of light and precise cutting, laser-cut panels bring a unique blend of artistry, functionality, and innovation to architectural design.
laser cut cladding examples (above)
laser cut balustrade infill examples (above)
Importance of structurally assessing your laser cut panels
Structural assessment of panels used for balustrade infill and cladding is of utmost importance due to considerations related to pedestrian loading and wind forces. Balustrades and cladding panels are vital components of a building’s envelope, providing safety, security, and aesthetic appeal. Panels in these applications are subjected to various loads, including the weight and impact forces exerted by pedestrians and the dynamic pressures generated by wind. It is crucial to assess the structural performance of these panels to ensure their strength, stability, and resistance to deflection under such loads. Rigorous analysis helps determine the suitability of the chosen materials, their thickness, and the overall design configuration to withstand the anticipated forces. Through accurate assessment, structural engineers can ensure that the panels meet safety standards, minimize the risk of failure, and maintain their integrity over time. Additionally, a well-designed and structurally sound balustrade or cladding system enhances the overall architectural quality and durability of a building, fostering confidence and satisfaction among occupants and stakeholders.
Preventing localized deflection and permanent deformations
Complex patterns in laser-cut panels can present a particular challenge as they may lead to localized deflection and potentially permanent deformation of the pattern itself. This issue arises due to the increased number of small, intricate cuts in the material, which can weaken its overall structural integrity. When subjected to loads, such as pedestrian forces or wind pressure, these thinner sections within the pattern may experience higher stress concentrations and exhibit greater deflections compared to the surrounding areas. Moreover, repeated loading over time can result in permanent deformation or even failure of the delicate pattern elements.
Using structural FEA to improve my laser cut pattern
Structural analysis using finite element analysis (FEA) can play a crucial role in identifying regions of concern and quantifying improvements for a better outcome. By converting the laser-cut panel into a finite element model, we can simulate the behaviour of the panel under various loading conditions. The FE analysis provides valuable insights into stress distribution, deflection patterns, and potential failure zones within the finer pattern. By examining these results, we can identify areas of high stress and excessive deflection that may lead to permanent deformation.
With this information, we can propose design modifications to enhance the structural performance of the panel. This could involve adjustments to the pattern layout, reinforcement in critical areas, or changes to the material thickness. By iteratively analysing different design configurations using FE plate analysis, we can also quantify the improvements achieved with each modification. This process enables us to optimize the panel’s structural behaviour, ensuring reduced deflection, improved load-bearing capacity, and minimized risks of permanent deformation, ultimately leading to a better overall outcome for the laser-cut panel.
Structural sign-off of laser cut panels
Once we have run the finite element plate analysis and agreed any changes with you, we can issue you the final digital pattern file (in DXF or DWG format) and also provide a Producer Statement (AKA design certificate, PS1) for structural design. The raw CAD file can be used directly by the steel fabricator for cutting and the Producer Statement can be used by your local planning authority for attaining building consent (e.g. for a balustrade where fall of height exceeds 1m).
Our laser cutting assessment service
See below our process. We prefer to receive your proposed pattern as either a digital 2D (e.g. DWG or DXF) or 3D file (e.g. Sketchup, Revit, Tekla, etc.). If required we can also convert from artwork in picture format (JPG or PNG) but note that this conversion often requires more refinement to achieve smooth curves. With this input we then setup and run our full finite element plate analysis. We have developed proprietary software that lets us automatically convert digital lines to FE plate with cut-outs. This automated process is shown in the video below.
Overall this process from input to sign-off can be run in approximately 2 days.
