Bell Steel Fabrications has replaced a ten-year-old flat-bed CO2 laser with a new 8 kW fibre laser system from BLM.
The fabricator manufactures a variety of products for UK and overseas customers as well as bespoke stainless steel silencer and exhaust systems for classic cars, which accounts for 40%.
The company has been using a BLM electric tube bender for some years and turned to them when it wanted to replace the old laser.
Managing Director Matthew Bell said: “We looked at three potential machine suppliers, but felt the BLM offered the best price and quality. So we opted for one of their LS7 3015 models, which was installed in March 2026.”
Fibre lasers have largely taken over from CO2 for cutting sheet metal, as they are less costly to run and maintain. They are also more compact, with fewer moving parts and no mirrors requiring regular alignment. They waste far less energy during beam delivery and convert more of their output into usable laser power. Moreover, gas usage is less with a fibre laser, as it needs only an assist gas, either nitrogen or oxygen, whereas a CO2 model also uses lasing and purge gasses. Mr Bell estimates that his company will save £20,000 a year in electricity and gas costs.
A vast range of components is produced in the machine from mild steel, stainless steel or aluminium, a large proportion of which are formed on a CNC press brake. They range from brackets, flanges and silencer baffles for classic car exhausts, to other vintage vehicle fittings like fuel tank, radiator, clutch, gearbox and chassis parts, to structural steelwork, architectural metalwork, mounting platforms for industrial machinery, bicycle racks, truck ladders and even fabrications that form part of draught beer dispensing units. Coded welders among the company’s 21 employees provide TIG, MIG, MMA and fusion welding services across the full range of materials processed.
Bell Steel Fabrications prides itself on being a solutions provider and partner, not just a subcontractor. While its products cannot be described as cheap, its management has always regarded value for money for its customers as a core principle. It therefore looks to suggest design changes where appropriate to lower production costs and once a project is agreed, to program jobs to be completed as cost effectively as possible.
In the latter respect, Mr Bell points to a key feature of the BLM LS7 that allows very rapid and economical laser cutting of multiple repetitive features, like dense grids of holes. Called Fly Cut, it avoids the traditional stop-start laser cutting of each individual shape before moving on to the next. In the case of a square or rectangular hole, a conventional production route involves acceleration of the head to cut one side and then three further direction changes to produce each individual hole.
In contrast, Fly Cut synchronises the movement of the cutting head with rapid switching of the laser beam. The control identifies all horizontal lines in a grid of holes and cuts them in a single, continuous sweep across the sheet. The head moves at a high and constant speed while the laser beam pulses on and off where the holes need to be. After completing the horizontal passes, the machine repeats the process for the three other orthogonal directions. In this way, a time saving of up to 70 percent can be achieved for this part of the cycle.
It is notable also that fewer stops and starts translate into less stress on the linear motors and drive systems, potentially extending the lifespan of the machine's motion components. To cut grilles successfully in this manner, the machine has to be precise and rigid to ensure that the lines meet at the corners. So Fly Cut not only saves cycle time but is also direct proof of the quality of a BLM machine.
Production at Bell Steel Fabrications is characterised by small batch sizes and one-off prototypes, with large runs being relatively uncommon. For this reason, Mr Bell chose not to automate material transfer to the BLM LS7 at this stage. However, if a future need arises, tower storage and handling systems are available from BLM to work in conjunction with the standard, dual-table shuttle system of the fibre laser machine.
Investment in BLM Group’s LS7 fibre laser profiling machine marks a significant step forward for Bell Steel Fabrications, delivering measurable cost savings, increased productivity and enhanced process flexibility. By combining advanced laser technology with a commitment to engineering excellence and customer value, the company is well positioned to expand its capabilities and remain competitive in a demanding subcontract manufacturing environment. The transition not only modernises the company’s production infrastructure, but also reinforces its reputation as a forward-thinking fabrication partner.