Metal Solid Shield Cutting



The Gemini-6 is a high performance fiber laser machine for cutting metallic tubular shields, such as that seen in high temperature thermocouples. It has a rotary and a linear optical assembly to allow a circumference cut as well as a number of longitudinal slits. This makes it easy to remove the metal jacket by gently flexing the cable and squashing the slug. The laser does not damage the inner conductors. The stripping process is repeatable and clean.

Laser wire stripping offers an effective alternative to mechanical methods, which are less able to cope with the new generation of small gage wires and can cause damage to the conductors from burring.

Features and Benefits

  • Clean and precise - damage-free stripping, with minimal burring along cut edge; fewer rejects of high value parts.
  • Easy to configure - custom control system enables simple programming of strip length, strip speed and number of passes. 
  • Flexible and versatile - quick loading of single cables up to 1 mm (0.04") metal wall thickness; parts can be cut from 1.5 mm (0.06") to 10 mm (0.4") outer diameter and up to 100 mm (4") slitting length.
  • Effortless stripping - operator inserts part into the system and selects a pre-programmed recipe from a list on the the color touchscreen, thereby activating stripping to pre-set parameters.
  • Safe - Class 1 enclosure around a Class 4 laser with safety lock door.
  • Low maintenance - no laser or machine wear parts. Runs from a standard single phase 230V / 120V electrical supply requirement.

Materials Processed

The Gemini-6 laser system is optimized for cutting any solid metal shielded cables and wires.  Examples include:

  • high temperature sensors and thermocouples
  • RF and microwave connections
  • RF and microwave medical ablation probes
  • Armoring for under-sea fiber optic cables.

Stripping Range

The Gemini-6 laser system cuts metal round parts:

  • Up to a 1 mm (0.04") wall thickness
  • From 1 mm (0.04") to 10 mm (0.4") outside diameter.
  • Slitting length up to 100 mm (4").

Technical Data (preliminary)

Min. Outer Cable Diameter

1 mm (0.04")
Max. Outer Cable Diameter 10 mm (0.4")
Stripping Length Increments 0.01 mm (0.001")
Strip types scribes, cuts and area ablation
Max. Stripping Length 100 mm (4")
Speed up to 2000 mm/s (80"/s).
Cable Loading

Single cable port

Dimensions (W x D x H)

950 x 1274 x 1586 mm (37.5 x 50 x 62.5")

More Info

The Laser Wire Solutions Gemini-4 cuts tinned micro-coax shield and aluminized foils as well as being able to ablate some bonded foils. The laser is strongly absorbed by the metallic shield causing it to vaporize. The laser is pulsed with very short duration pulses to ensure no heat is built up in the shield that could damage the underlying insulation. Once cut, the shield can be snapped off revealing the underlying layers. When scribing a foil or tinned shield, the laser light never penetrates to an underlying layer. When cutting foil it is often the case that the light does penetrate - in which case the effect on the underlying plastic layers has to be carefully assessed.

The main applications are for micro-coax shields where the coax outer diameter is less than 0.25 mm (0.01") and for cutting foil shields found in twin-ax type cables.  Using the color touchscreen, the operator selects the desired settings (laser power, laser speed and strip positions)  from the preprogrammed library and all parameters are automatically set.  This unique software system avoids the need to program each laser move individually.

Gemini-4 begins the cutting process when the Operator starts the process via the touchscreen or via the optional footswitch.

The wires/cables are held in position via a configurable fixture plate or if the application allows, through a single entry port.