What is the process to cut a thread on metal by laser?

If you’ve ever tried tapping metal threads manually, you know how slow, error-prone, and costly it can get—especially at scale. But what if the laser cutter could do most of the work for you?

To cut threads in metal using a laser, we first use a fiber laser cutter to make a precise pilot hole, typically undersized by 10–20%. The threading is then finished using a CNC tapper or manual process. This method saves time and extends tool life.

Laser thread preparation is now standard in many high-precision manufacturing workflows. In this article, I’ll walk you through the process, explain how fiber lasers help, and share insights from real customers who’ve streamlined production with this method.

What is the process of laser cutting metal?

Laser cutting is a game-changer in metal fabrication, but it's not magic—it’s engineering precision driven by light.

The process of laser cutting metal involves focusing a high-energy laser beam onto the surface of the metal to melt, burn, or vaporize the material. A nozzle with assist gas (typically oxygen or nitrogen) blows the molten material away, creating a clean, narrow cut.

How Fiber Laser Cutting Works

Let’s break it down into structured steps and considerations.

Step-by-Step Metal Laser Cutting

Step	Description
1. CAD Design	Create a drawing or import a file (DXF, AI, etc.)
2. CAM Preparation	Nest the design, set parameters like power, speed, gas
3. Focus the Beam	The fiber laser is auto-focused to optimize energy delivery
4. Assist Gas	Oxygen (for carbon steel) or Nitrogen (for stainless/aluminum) is injected
5. Execution	The laser cuts with micron-level precision1
6. Edge Quality Check	Minimal dross or burrs—often no secondary finishing needed

At Kirin Laser, we specialize in fiber laser cutting² systems that consistently deliver sharp, burr-free cuts. This is essential when prepping pilot holes for tapping threads, where clean edges reduce tap breakage and tool wear.

The Real Advantage

I’ve seen many customers move away from plasma or CO₂-based cutting systems because of excessive edge hardening and inconsistent cut width. Fiber lasers solve these issues with:

• Narrower kerf (cut width)
• Better edge smoothness³
• Minimal heat-affected zones
• Reduced post-processing

How to cut a thread in metal?

This is where precision meets practicality. A thread in metal isn’t something you can just burn in—you need a process.

To cut a thread in metal, start by laser-cutting a pilot hole slightly smaller than the thread’s nominal diameter. Then use a tap—manually or with CNC—to form the thread. Laser-cut holes reduce wear on taps and ensure consistent thread engagement.

Why Laser-Cut Pilot Holes?

Let’s take a practical look:

Tapping Preparation vs Traditional Drilling

Method	Speed	Accuracy	Tool Life	Post-Processing
Manual Drilling + Tapping	Slow	Variable	Short	High
Laser + CNC Tapper	Fast	Precise	Long	Minimal

In one project, I worked with a client producing custom enclosures. They used to drill and tap manually. The switch to our fiber laser cutters⁴ allowed them to batch-cut pilot holes⁵ directly from CAD. With a tight tolerance and smooth entry, their CNC tapper⁶ could work twice as fast. The reject rate dropped by 40%, and they scaled production without hiring more labor.

Key Considerations for Laser + Tap Workflow

• Undersize Pilot: 80–90% of the tap diameter
• Edge Cleanliness: Fiber lasers keep edges smooth
• Thermal Effects: Minimal hardening with proper parameters
• Automation: Easily pairs with robotic tapping systems

What type of laser is best for cutting through metal?

With so many laser types out there, it’s easy to get confused. But in metal, only one wins consistently.

Fiber lasers are the best type of laser for cutting through metal. They offer high energy efficiency, low maintenance, fast cutting speeds, and excellent edge quality. They're especially effective for stainless steel, aluminum, and carbon steel.

Fiber Laser vs Other Types

Let’s compare the contenders.

Metal Laser Comparison Table

Laser Type	Best for	Limitations
Fiber Laser7	All metals incl. reflective (aluminum, copper)	Costlier than CO₂ upfront
CO₂ Laser	Non-metals, acrylic, wood	Poor metal performance
Crystal (Nd:YAG)	Very thin metal, medical use	Fragile, short lifespan

From my experience at Kirin Laser, fiber lasers are the backbone of most modern metal shops. They’re also the least maintenance-intensive⁸ and can run continuously in production lines. For thread preparation, their beam quality makes all the difference. You get cleaner holes, tighter tolerances, and better tap alignment.

Why Customers Prefer Fiber

• Higher Cutting Speeds: Up to 4x faster than CO₂ on metal
• No Mirror System: Uses fiber optics—less alignment needed
• Power Options: Ranges from 1kW to 20kW depending on thickness
• Plug-and-Play Integration: Works well with automation cells

If you’re dealing with high-mix, low-volume manufacturing or tight turnaround projects, fiber is the only way to go.

How does a laser cutter work step by step?

Understanding the steps helps you diagnose, optimize, and improve efficiency. So let’s lay it out.

A laser cutter works by following these steps: design import, parameter setup, laser focusing, gas assist, material melting or vaporization, and removal of molten metal using pressure. This forms a cut that is clean, accurate, and repeatable.

Full Workflow Walkthrough

Here’s how a typical job runs on a Kirin Laser fiber cutter⁹:

Laser Cutting Step Table

Step	Task	Note
1	Import CAD	DXF, SVG, or AI format
2	Assign Parameters	Power (W), speed (mm/s), gas type, focus offset
3	Focus Beam	Autofocus lens adjusts in real time
4	Cut Execution	Starts cut via G-code or software command
5	Assist Gas Push	Blows molten metal out of the kerf
6	Edge Inspection	Camera or operator check

I often recommend our clients to document and optimize each of these steps. For example, by tuning nitrogen pressure and beam focus, one customer reduced their burr rate¹⁰ by 60%—meaning less grinding and polishing downstream.

Pro Tip

Add an extra quality check¹¹ right after the cut. If you're preparing for threading, run a quick go/no-go gauge on pilot holes. That one step can prevent expensive tap breakage later.

Conclusion

Laser-cutting threads in metal isn’t about skipping the tap. It’s about preparing better. With fiber lasers, we can produce cleaner, tighter pilot holes that reduce tool wear and increase threading speed. At Kirin Laser, I’ve seen how switching to laser-cutting¹² pilot holes can cut costs, reduce rejects, and open the door to automation. Whether you’re upgrading a small fab shop or scaling industrial production, precision starts with the beam.