A master thesis from Aalborg University
Assessing Magnetic Levitation for Flexible Laser Processing in Low-Volume Sheet Metal Manufacturing
[Undersøgelse af Magnetisk Levitation til Fleksibel Laserbearbejdning i Lavvolumen Plademetalproduktion]
Author(s)
Term
4. term
Education
Publication year
2025
Submitted on
2025-05-29
Pages
110 pages
Abstract
This master’s thesis investigates the potential of magnetic levitation in laser-based processing, focusing on improving flexibility, quality, and cost-efficiency for low- volume production and rapid prototyping. As demand for customisation and sus- tainable manufacturing increases, the study explores how component-level design changes can influence system performance across these aforementioned objectives. A two-stage literature study identifies a gap in the industrial adoption of laser form- ing, which remains underutilised compared to laser cutting, welding and engraving. To address this, engineering specifications based on industry stakeholder interviews and literature are defined, and two fixture approaches are proposed. Approach Two, involving a cutout template, is selected for its adaptability and simplicity. The magnetic levitation system is developed using empirical parameters and assessed against the relevant engineering requirements. Results show that the desired flexi- bility is achieved, and the system, when scaled, can meet low-volume order sizes. Although angle accuracy deviates from the targeted value due to open-loop control, the process allows for salvage of under-formed parts, reducing the cost of poor qual- ity (hidden and visible cost stemming from poor quality). Cost analysis confirms that magnetic levitation is a viable option for low-volume and prototyping applications, offering consistent unit costs without tooling expenses. In conclusion, magnetic levitation in laser-based processing shows strong industrial relevance and presents a promising foundation for an integrated, "all-in-one" laser processing platform for the sheet metal industry.
Keywords
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