Introduction
Looking to cut long, heavy steel tubes quickly and accurately? SENFENG’s SF15056HT fiber laser and SF9035GNT system deliver exactly that—empowering high-volume, automated production with minimal labor and minimal scrap. This case study shows how a U.S. foundation products manufacturer overcame bottlenecks and boosted output using SENFENG’s solutions.
The Project
Country: United States
Industry: Building & Natural Gas Foundation Products
SENFENG Equipment: SF15056HT laser tube cutter; SF9035GNT fiber laser
Application: Cutting carbon steel tubes (up to 15 m long, Ø 70–556 mm, 13 mm wall), plus H-beams, I-beams, angles, and C-channels
Customer Background & Challenges
The customer is a U.S.-based engineering and manufacturing company serving the building and natural gas industries. With decades of experience, the company has stayed true to its mission: “Elevating standards of the foundation industry by expediting reliable quality solutions that provide a safe environment for all.” They engineer, design, and manufacture high-quality foundation products—including custom residential solutions, helical piles, steel caps, grout-filled piles, utility foundations, and structural frames—earning praise from clients both domestically and internationally.
Despite decades of success, they faced significant constraints:
- High Daily Throughput:The factory processes a large volume of tubes daily, requiring reliable, high-speed equipment to keep up with demand.
- Low Automation Level:Existing tube cutting equipment relied heavily on manual loading, unloading, and positioning, increasing labor costs and slowing production.
- Limited Flexibility for Rush Orders:Manual operations and low efficiency made it difficult to respond quickly to urgent or last-minute fabrication tasks.
Thanks to SENFENG’s SF9035GNT fiber laser and SF15056HT laser tube cutter, the company has achieved a more automated, efficient, and scalable approach to metal tube processing.
Solution: SF15056HT Laser Pipe Cutter
The company required a versatile solution capable of cutting carbon steel tubes (up to 15 m long, Ø 70–556 mm, 13 mm wall) along with structural profiles such as H-beams, I-beams, angle bars, and C-channels. Based on these requirements, SENFENG recommended the SF15056HT fiber laser, designed for large-diameter, long-length cutting. Key benefits:
Broad Material & Profile Compatibility
- Capable of cutting long and heavy round, square, and rectangular tubes with high precision and efficiency.
- Handles I-beams, H-beams, angle steel, and C-channels without manual repositioning.
Extended Cutting Length (Up to 15 m)
- Extra-long bed supports 15 m tubes, 2–5× longer than many competitors.
High Automation & Labor Savings
- Automatic loadingand unloading systems drastically cut operator intervention.
- Intuitive touchscreen HMI for quick parameter input and nesting.
Precision & Reduced Scrap
- Unique chuck, bed, and follow-up motion design enables zero-tail cutting, minimizing material waste.
- High cutting precision significantly reduces scrap rates and lowers overall production costs.
With about 80 % of the client’s tube-cutting tasks covered, the SF15056HT became the centerpiece of their modernization plan.
Pre-Sales Collaboration & Local Support
Demo & Sample Cutting
At SENFENG’s U.S. facility, the customer saw the metal pipe laser cutting machine in action:
- 500 mm × 15 m Carbon Steel Tube:Burr-free, round end faces, minimal heat-affected zones.
- I-Beam Sample:Cleanly cut flanges and webs without repositioning.
Operators were impressed by the high cut quality and user-friendly interface, which proved that the SF15056HT could streamline their workflow.
Onsite Assessment & Layout Optimization
SENFENG’s engineers visited the customer’s factory to finalize installation details:
- Floor Space & Foundation:Confirmed available floor space. Provided layout plan and foundation specs for proper machine placement and leveling.
- Power:Verified the proper three-phase supply with surge protection.
- Workflow Layout:Recommended optimal placement for raw material racks, loaders, scrap conveyors, and finished-goods zones.
This hands-on planning secured seamless integration and minimized downtime—hallmarks of SENFENG’s localized, professional service.
Additional Order: SF9035GNT Fiber Laser
To handle smaller tubes (≤ 9 m) and add bevel-cutting capability for welding prep, the customer ordered the SF9035GNT 8 kW Tube Laser. Key highlights:
- 45° Bevel Cutting (V-Groove):Precise bevels on Φ20~Φ350mm tubes accelerate welding assembly.
- Compact Bed:Fits tighter shop spaces, with fast cycle times.
- Automated Feeding & Nesting:Similar HMI and automation features streamline operations.
After a live demo on a 273 mm × 6 m tube with a 45° bevel, the customer finalized the order.
Why SENFENG’s Tube Laser Solutions Stood Out
When comparing SENFENG to Bodor, HSG, Mazak, Trumpf, Amada, and BLM, the customer cited three decisive advantages:
Seamless Production Line Integration
- SF15056HT (15 m, Ø 70–556 mm) + SF9035GNT (9 m, Φ20~Φ350mm) cover 95 % of their tube requirements.
- Bevel-cutting and zero-tail features match their need for precision, minimal scrap, and high-volume output.
Responsive Local Support & Parts Availability
- SENFENG’s U.S. branch maintains a trained service team, local spare parts stock, and fast
- Expertise in regional electrical and environmental conditions ensures reliable uptime.
Competitive Total Cost of Ownership (TCO)
- Zero-tail cutting and high automation reduced scrap and labor costs dramatically.
- Payback for the SF15056HT was projected under 18 months, delivering strong ROI compared to higher-end European brands.
These factors cemented SENFENG as the top choice—combining technical performance, price, and local service support.
Installation & Training
After the SF15056HT and SF9035GNT arrived, SENFENG’s field service team:
- Set Up & Calibration:Assembled machines, connected the fiber lasers, chillers, and control cabinets, then performed basic leveling and alignment checks.
- Operator Training:Conducted a concise three-day program covering: basic machine operation, nesting software, bevel programming, and routine maintenance tips.
- Safety & Best Practices:Reviewed safe loading/unloading procedures, emergency stops, and forklift handling of heavy tubes.
Within two weeks, the customer’s staff was fully proficient, and both machines were running high-volume jobs with minimal support.
Key Outcomes & Business Impact
- Increased Production Capacity:Monthly tube processing surged significantly compared to previous methods.
- Reduced Material Waste:Zero-tail cutting minimized scrap, resulting in substantial cost savings.
- Lower Labor Costs:Automated loading/unloading greatly reduced manual handling, allowing operators to focus on higher-value tasks.
- Consistent Part Quality:High bevel accuracy and low scrap rates across both heavy and smaller tubes.
- Expanded Business Opportunities:Won new foundation projects for pipeline installations, further enhancing market reputation.
Conclusion
SENFENG’s SF9035GNT fiber laser and SF15056HT laser tube cutter delivered unmatched power, automation, and local support—enabling this manufacturer to achieve rapid ROI, superior cut quality, and expanded market reach. For any fabricator seeking high-capacity, precision tube cutting backed by responsive service, SENFENG offers the ultimate turnkey solution.
