Industrial manufacturing has undergone a radical transformation in precision and speed over the last decade. According to recent industry analyses, the global laser cutting market is projected to grow at a compound annual growth rate exceeding 10 percent through 2030. This surge is driven by the demand for high-tolerance metal fabrication in aerospace, automotive, and heavy machinery sectors. Kern Laser Systems has been at the forefront of this evolution since 1982, providing robust, large-format solutions that bridge the gap between traditional CNC machining and modern digital fabrication.
Understanding Industrial Laser Cutting
Industrial laser cutting is a thermal cutting process that uses a high-power laser to melt, burn, or vaporize material. The core mechanism involves directing a focused beam onto the workpiece, while a assist gas blows away the molten material to create a clean kerf. This method allows for intricate geometries that are impossible to achieve with traditional mechanical blades.
For metal fabrication, the choice of laser source is critical. Fiber lasers are the industry standard for cutting steel, aluminum, and brass due to their high electrical-to-optical efficiency and superior beam quality. Conversely, CO2 lasers remain versatile for non-metallic materials and thin metals, offering a cost-effective entry point for mixed-material shops.
The shift toward large-format systems allows manufacturers to process full sheets of material without secondary joining operations. This reduces labor costs and minimizes material waste. Kern’s approach to large-format cutting emphasizes stability and precision, ensuring that even at maximum table sizes, the cut quality remains consistent.
Kern Laser Systems Overview
Kern Laser Systems is a leading manufacturer of large format laser cutting and laser engraving equipment. Since opening their doors in 1982, Kern is proud to have installed thousands of large format laser cutters and engravers worldwide. The company was founded by Gerald Kern with the objective to design and manufacture top-quality industrial laser cutting and laser engraving machines to meet demanding production schedules.
The company headquarters are located in the beautiful lakes country of Minnesota. The facility consists of a modern 90,000 sq. ft. building with 50 full-time employees. This Midwest-based manufacturing hub ensures that every machine is built with rigorous quality control standards. Kern specializes in large format fiber and CO2 laser cutting systems. Additionally, Kern’s machines are capable of processing plastic, foam, acrylic, textiles and metal cutting.
Today, Kern Laser Systems is proudly owned and operated by the first and second generations of the Kern family. Their goal moving forward is to constantly improve their products, improve processing times and continue to offer their customers the best customer service in the laser industry. This family-owned heritage translates to a dedication to long-term customer relationships rather than short-term sales.
Fiber vs. CO2 for Metal Applications
Selecting the right laser technology depends on the specific materials and thicknesses your facility handles daily. Understanding the differences between Fiber and CO2 sources is essential for maximizing return on investment.
The FiberCELL Advantage
The FiberCELL is Kern’s compact sheet metal cutting laser capable of cutting stainless steel, mild steel, aluminum, brass and copper. A Class 2 safety enclosure allows the CNC laser system to be placed in high-traffic areas such as busy factory floors and university classrooms. Fiber lasers offer faster cutting speeds on thin to medium gauge metals compared to CO2 sources. They also require less maintenance because they have no mirrors or gas lasers to align.
The OptiFlex Versatility
The OptiFlex is a high performance, large format laser cutting and engraving system. This is the most popular and versatile machine in Kern’s product line. The OptiFlex is ideal for processing of metal, acrylic, wood, textiles and foam while also featuring high-speed engraving capabilities. While primarily a CO2 system, it offers exceptional flexibility for shops that need to switch between metal and non-metal materials frequently.
Key Systems Comparison
Choosing the correct system requires evaluating your throughput needs, material variety, and budget. The table below outlines the core capabilities of Kern’s primary industrial offerings.
| System Name | Primary Technology | Best For | Key Feature |
|---|---|---|---|
| OptiFlex | CO2 Laser | Mixed materials (Metal, Acrylic, Wood) | High-speed engraving and large format cutting |
| FiberCELL | Fiber Laser | Pure metal cutting (Steel, Aluminum, Brass) | Compact design with safety enclosure |
| LaserCELL | CO2 Laser | High-traffic environments | Class 2 safety enclosure for open floor use |
| EcoFlex | CO2 Laser | Entry-level large format cutting | Economical price point with high productivity |
Operational Advantages
Implementing industrial laser cutting systems offers significant operational benefits beyond simple speed. Precision is paramount in modern manufacturing. Kern’s machines feature the K-Vision Camera system, which provides precise alignment and efficient cutting of preprinted materials. This camera registration technology ensures that even when cutting complex shapes from large sheets, the accuracy remains within tight tolerances.
Safety is another critical component of industrial operations. The LaserCELL and FiberCELL systems feature fully enclosed Class 2 designs. This allows these machines to be placed in high-traffic areas such as busy factory floors and university classrooms without compromising operator safety. This integration reduces the need for separate safety cages, saving valuable floor space.
Furthermore, Kern’s commitment to Made in the USA manufacturing ensures that spare parts and technical support are readily available. Operating a factory in a small town in the Midwest certainly has advantages. Employees at Kern have the good fortune of knowing each other through work, family, sports and community activities. Bringing those relationships to the workplace combined with a great Midwestern work ethic makes for a dynamic and exciting place to work. This dedication translates to higher quality control and more reliable machine performance for your business.
Key Takeaways
- Kern Laser Systems was founded in 1982 by Gerald Kern, establishing over four decades of industry expertise.
- The company operates from a 90,000 sq. ft. facility in Wadena, Minnesota, employing 50 full-time staff.
- The FiberCELL system is specifically designed for pure metal cutting, including stainless steel and aluminum.
- The OptiFlex is Kern’s most popular system, offering versatility across metal, acrylic, and wood.
- K-Vision Camera technology enables precise alignment for preprinted materials and complex geometries.
- All Kern systems are proudly manufactured in the USA, ensuring strict quality control standards.
- Class 2 safety enclosures on LaserCELL and FiberCELL allow for safe operation in open, high-traffic environments.
Frequently Asked Questions
What materials can Kern laser systems cut?
Kern laser systems are capable of processing a wide range of materials. Fiber systems excel at cutting metals such as stainless steel, mild steel, aluminum, brass, and copper. CO2 systems like the OptiFlex and LaserCELL can cut metals as well as non-metals including acrylic, wood, leather, foam, and textiles.
Is Kern Laser Systems a family-owned business?
Yes, Kern Laser Systems is proudly owned and operated by the first and second generations of the Kern family. Derek Kern serves as President/CEO of Kern Laser Systems, while Aaron Kern is the President/CEO of Kern Technologies. This family leadership ensures a long-term commitment to product quality and customer service.
What is the K-Vision Camera system?
The K-Vision Camera is a registration technology integrated into Kern’s laser systems. It provides precise alignment and efficient cutting of preprinted materials by automatically detecting registration marks on the substrate. This feature is particularly valuable for applications involving vinyl, signage, and pre-cut parts.
Where are Kern laser machines manufactured?
All Kern laser cutting and engraving equipment is manufactured in the USA. The company’s headquarters and production facility are located in Wadena, Minnesota. This domestic manufacturing process allows for rigorous quality control and faster delivery times for North American customers.
What warranty does Kern offer on their CO2 laser sources?
Kern provides a 3 Year Warranty on CO2 laser sources. This warranty covers the high-quality super pulsed laser sources used in their OptiFlex and LaserCELL systems, ensuring long-term reliability and reduced downtime for industrial users.
Can Kern lasers be used in educational settings?
Yes, systems like the LaserCELL and FiberCELL are designed with Class 2 safety enclosures. This allows them to be safely placed in high-traffic areas such as busy factory floors and university classrooms, making them ideal for educational and collaborative manufacturing environments.
Contact Kern Laser Systems
Ready to upgrade your industrial fabrication capabilities? Kern Laser Systems offers tailored solutions for every manufacturing need. Whether you require a compact metal cutter or a large-format versatile engraver, their team is ready to assist. Visit the Contact Kern Laser Systems page to request a quote or schedule a consultation. You can also explore their technical blog for more insights on laser processing and material testing.