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 (up to 4). 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 Gemini-6 from Laser Wire Solutions has been designed for the stripping of wires with outer metallic jackets. The process is fully automated. The wire is inserted into the single entry port where it is held in position by a mechanical gripper. The laser beam is directed towards the wire by means of a unique auto-focusing combined linear and rotary optical assembly. This allows for full 360º radial stripping together with up to four separate axial strips. Wires up to 10 mm (0.4") outer diameter can be processed. The stripping cycle is triggered by means of a touchscreen or optional foot switch.

Main applications for this laser stripper include high powered RF cables and high temperature mineral-insulated thermocouples, where the Magnesium Oxide (MgO) powder forms an effective and reliable barrier between the laser and the inner conductor wires.