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 generally more electrically efficient than legacy CO2 cutting sources. The example rows here reflect internal reference values; actual wall-plug efficiency and system power vary by brand, configuration, and duty cycle.
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 cutting sources usually operate at a lower electrical efficiency than comparable fiber sources. In many real-world installations, measured total system kW for CO2 equipment is several times higher than for fiber systems of similar cutting capacity, but your exact ratio should come from your own equipment data.
Operating Cost Comparison
Annual electricity costs at different usage levels
6 kW Fiber Laser
3 kW CO2 Laser
Illustrative 5-year energy difference: Using the duty cycles and rates shown in this example, the modeled electricity spend for the fiber system is several thousand dollars lower per year than for the CO2 system, adding up to tens of thousands of dollars over five years at 40 hours/week. Your actual savings will depend on your own run-hours, tariffs, and measured kW draw.
Conversion & Demand Planning
Keep these factors handy when translating OEM specs into facility load studies and quotes.
Quick conversions
- Amps = (kW x 1000) / (Voltage x 1.732 for 3-phase).
- kWh per shift ≈ average kW draw x hours; you can add an extra margin for idle or partial-load time based on your own logs (some facilities start with a 10-15% adder as a rough check).
- Demand charge impact ≈ peak kW x your utility's demand rate (for example, some tariffs quote single- to low-double-digit dollars per kW of demand).
Record the worst-case scenario (pierce, thick plate) for electrical engineers and utility filings.
Facility checklist
- Verify transformer tap (208 vs 480 V) before scheduling installs.
- Log chiller/exhaust location to size HVAC makeup air.
- Feed measured draw into the Energy calculator to compare against utility bills.
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 (example): average draw can be relatively close to peak power when uptime is high.
- Job shop example: including setup, loading, and programming time often pulls the average below peak; use your own machine logs to quantify this.
- Prototype/low volume: frequent stops and changeovers usually reduce average draw further relative to the nameplate peak.
Electrical Service Requirements
Ensure your facility has adequate electrical capacity:
- 1-3 kW fiber: 208V 3-phase, 30-50A service
- 4-8 kW fiber: 208V or 480V 3-phase, 60-100A service
- 10-15 kW 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: hot summer conditions can noticeably increase chiller power draw compared to cooler seasons.
- Chiller efficiency: newer, higher-efficiency designs can use significantly less power than older models; check vendor data for your specific unit.
- Maintenance: poor airflow and dirty condensers can increase power consumption; use your maintenance logs and meter readings to quantify the impact.
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: Turning off equipment during extended breaks (lunch, overnight) can avoid unnecessary idle kWh; in some shops this reduces total energy use by a noticeable margin, depending on schedules and tariffs.
Energy Efficiency Optimization
1. Optimize Cutting Parameters
In some processes, operating slightly below maximum speed and power can reduce energy use while still meeting cut quality requirements. Using significantly more power than needed for the job can waste energy, so validate parameter changes with test cuts and, where possible, meter readings on your own machine.
2. Maintain Chiller Efficiency
Clean condenser coils regularly and follow manufacturer maintenance schedules. A well-maintained chiller can use noticeably less power than a neglected one. Vendors of variable-speed compressor chillers often publish efficiency improvements compared to older fixed-speed units; use their data together with your own measurements to estimate potential savings.
3. Batch Similar Jobs
Minimize start/stop cycles where practical. Startup and warmup periods add non-productive time at higher power draw. Batching similar jobs can reduce this overhead; some shops see meaningful energy reductions when grouping work instead of cycling equipment frequently.
4. Consider Time-of-Use Rates
Many utilities offer lower rates during off-peak hours (nights, weekends). Shifting part of your production to off-peak windows can materially reduce electricity spend where time-of-use pricing is available. Check your actual tariff table to quantify the impact.
5. Monitor Power Factor
Poor power factor in your facility can result in utility penalties under some tariffs. Review your utility bills and metering data, and consult with your utility or an electrical engineer before adding power factor correction equipment. Many modern laser systems advertise improved power factor compared to older CO2 designs, but you should confirm this for your specific installation.
Energy Cost Workflow
Connect electrical data to the calculators so quotes, ROI, and shop rates share the same inputs.
- 1. Capture utility assumptions. Note $/kWh, demand charge ($/kW), and operating hours inside your sourcing log or Energy calculator presets.
- 2. Convert to hourly burden. Feed the measured kW and rates into the Hourly Rate calculator so gas, power, labor, and overhead align.
- 3. Push downstream. Reference the same energy burden when modeling payback in the ROI calculator and when pricing parts in the Laser Cutting calculator.