Laser Cleaning for Contract Manufacturing — Rust Removal

Anton Salomonson, Production Manager at Stoeryd AB (Tranås, Sweden), submitted an inquiry regarding the suitability of laser cleaning for their contract manufacturing operations. Stoeryd AB provides services including laser cutting, press braking, welding, powder coating, and assembly.

The company faces two specific cleaning challenges:

1. Vibratory tumbling bottlenecks. Certain articles are cleaned by vibratory tumbling, a process that is time-consuming and limits capacity. They seek an alternative for some parts.
2. Intermittent surface rust on sheet and tube stock. Large quantities of sheet metal and tube sometimes exhibit surface rust that must be removed before further processing or painting.

The customer is initially interested in renting equipment to conduct a practical evaluation, and requests a recommendation on suitable applications and equipment type.

YIHAI LASER’s response focuses on a pulsed fiber laser cleaning system as a flexible, non-contact, chemical-free method capable of addressing both applications, with a rental program designed to facilitate on-site testing.

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Process Assessment: Is Laser Cleaning Suitable for Stoeryd AB?

Laser cleaning uses short, high-energy pulses from a fiber laser to ablate contaminants—rust, oxide scale, oil, coatings—from a metal surface. The process is selective: the contaminant absorbs the laser energy and is vaporized, while the underlying metal reflects the beam and remains undamaged. It generates no abrasive media, no chemical effluent, and requires only electricity and, in some configurations, compressed air for debris removal.

The table below compares laser cleaning to Stoeryd’s current methods for the two identified applications.

Criterion	Vibratory Tumbling (Current)	Manual Rust Removal (Wire brush/grinder)	Pulsed Laser Cleaning (Proposed)
Process type	Mechanical abrasion in bulk	Manual mechanical abrasion	Non-contact photothermal ablation
Surface impact	Rounds edges, alters surface finish	Scratches, removes base metal	No measurable surface change, preserves dimensions
Edge and geometry access	Limited to external surfaces, parts collide	Manual, labor-intensive	Line-of-sight, can access corners, welds, internal features
Rust removal capability	Not designed for heavy rust	Effective but slow, risk of gouging	Effective on rust grades B–C, zero substrate loss
Chemical usage	Compounds and water	None	None
Labor requirement	Low (batch) but long cycle times	High (minutes per part)	Low (automated or handheld, seconds per area)
Energy/consumable cost	Media, compound, water treatment	Abrasive discs, brushes	Electricity (~0.5–1.5 kW), protective window
Pre-paint readiness	Requires cleaning/drying	Leaves dust, may need solvent wipe	Dry, clean, oxide-free surface ready for powder coat
Flexibility	Limited to tumbling barrel capacity	Any part, but operator-dependent	Handheld or robot-mounted, any part geometry

The assessment indicates that laser cleaning is well-suited to both applications. For rust removal on sheet and tube, laser cleaning removes rust and mill scale without removing base metal, leaving a clean surface ideal for welding or powder coating. For replacement of vibratory tumbling, laser cleaning cannot process bulk loads of small parts in a single cycle; however, for larger components, welded assemblies, or parts where edge rounding from tumbling is unacceptable, laser cleaning offers a faster, higher-quality alternative that does not damage fine features.

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Recommended Equipment for Evaluation

For Stoeryd AB’s evaluation, YIHAI LASER recommends a 500W pulsed fiber laser cleaning system. This power level provides a balance of cleaning speed and capital cost, suitable for rust removal on sheet and tube and for targeted cleaning of welded components. The system can be configured as a handheld unit for manual operation or integrated with a robot for automated processing of large sheets and tubes.

Recommended system specifications:

Parameter	YIHAI LASER 500W Pulsed Laser Cleaning System
Laser type	Pulsed fiber laser, 1064 nm
Average power	500 W
Pulse energy	Up to 50 mJ
Pulse duration	100–200 ns
Cleaning width	Up to 80 mm per pass (handheld)
Cleaning speed	Up to 10 m²/hour (rust, light)
Cooling	Water-cooled
Power supply	220–240 V, 50/60 Hz, single-phase
Weight (handheld gun)	1.5 kg
Interface	Touchscreen, multilingual (Swedish/English)
Safety	Class 4 laser, interlocked, protective goggles included
Mobility	Wheeled cart or portable case
Rental option	Available (minimum 4-week period, includes training and consumables)

For larger-scale automated cleaning of sheet and tube, YIHAI LASER also offers a 1000W system with a galvo scanner head and linear axes, which can be integrated into Stoeryd’s existing material handling lines. However, for initial evaluation, the 500W handheld system is recommended because it allows testing on multiple part geometries and rust conditions without requiring dedicated fixtures.

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Expected Performance and Evaluation Framework

During the rental period, YIHAI LASER proposes a structured evaluation program to quantify the benefits. The following table provides expected performance data and evaluation criteria for Stoeryd AB to assess during the trial.

Application	Test Part	Expected Cleaning Time	Expected Result	Evaluation Metric
Rust removal on 3 mm steel sheet (rust grade B)	300 × 300 mm coupon	30–60 seconds	Clean, bright metal, no base metal loss	Visual per ISO 8501-1, adhesion test after powder coat
Rust removal on 25 mm steel tube (rust grade C)	1 m length	1–2 minutes	Rust-free, weld-ready	Visual inspection, surface profile unchanged
Replacement for vibratory tumbling on welded bracket	Bracket with weld spatter and oxide	15–30 seconds per weld area	Clean weld, no rounding of holes/edges	Dimensional check, surface roughness Ra
Pre-paint cleaning on laser-cut parts	Cut edge with oxide tint	10–20 seconds per meter	Uniform clean edge	Cross-hatch adhesion test after painting

A successful evaluation would demonstrate:

• Rust removal to Sa 2.5 (near-white metal) per ISO 8501-1.
• No measurable dimensional change on cleaned parts.
• A cycle time reduction of at least 50% compared to current vibratory tumbling or manual rust removal for selected parts.
• Powder coating adhesion meeting Stoeryd’s internal standards without additional chemical pre-treatment.

YIHAI LASER’s application engineers will support the evaluation on-site or remotely, providing parameter optimization, safety training, and performance documentation.

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Economic Consideration: Operational Cost vs. Current Methods

The table below estimates the operational cost per square meter of cleaned surface for the three processes, excluding labor, based on typical industrial rates in Sweden.

Cost Element	Vibratory Tumbling (per m² of part surface, batch)	Manual Rust Removal (per m², wire brush/grinder)	500W Pulsed Laser Cleaning (per m², rust grade B)
Media/consumables	$0.20–0.50 (compound, media wear)	$0.30–0.80 (discs, brushes)	$0.05–0.15 (electricity, protective window amortization)
Electricity	$0.05	$0.02 (grinder)	$0.10–0.20
Labor	$2.00–4.00 (loading/unloading, long cycle)	$8.00–15.00 (manual, slow)	$1.00–3.00 (operator guides handheld or supervises automated)
Total cost per m²	$2.25–4.55	$8.32–15.82	$1.15–3.35

For manual rust removal, laser cleaning reduces cost per square meter by 70–80% and is significantly faster. For vibratory tumbling, the cost comparison is application-dependent: for large, single parts, laser cleaning is cheaper; for bulk small parts, tumbling remains more economical on a per-part basis, but laser cleaning offers superior edge quality and no dimensional change.

The rental option allows Stoeryd AB to validate these cost estimates on their own parts before committing to a purchase.

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YIHAI LASER Application Note

YIHAI LASER provides laser cleaning systems from 100W to 1000W for industrial applications. For Stoeryd AB, the 500W pulsed fiber laser cleaning system is recommended for initial evaluation. The system is available for rental with a minimum term of four weeks, including on-site setup, operator training, and all necessary safety equipment. A rental credit may be applied toward the purchase price if Stoeryd AB decides to acquire the system. The machine’s control interface supports Swedish and English, and the system is CE-certified.

For manufacturers considering laser cleaning as a replacement for vibratory tumbling or manual rust removal, YIHAI LASER’s application laboratory processes sample parts at no charge and returns cleaned samples with a process report, including cleaning time, surface quality data, and cost per part estimates.

Frequently Asked Questions

Is laser cleaning suitable for removing rust before powder coating?
Yes. Pulsed fiber laser cleaning removes rust and mill scale to Sa 2.5 (near-white metal) per ISO 8501-1, leaving a dry, clean surface that is ready for powder coating without additional chemical pre-treatment. It does not alter the surface profile or remove base metal.

Can laser cleaning replace vibratory tumbling for contract manufacturing?
For certain parts, yes. Laser cleaning is ideal for large components, welded assemblies, and parts where edge rounding or dimensional change from tumbling is unacceptable. However, for high-volume bulk small parts, vibratory tumbling remains more economical per part. A hybrid approach—tumbling for bulk parts, laser cleaning for large or precision parts—is often optimal.

What equipment does YIHAI LASER recommend for a first evaluation?
A 500W pulsed fiber laser cleaning system with a handheld gun is recommended for initial evaluation. It can be rented for a minimum of four weeks, includes training and safety equipment, and allows testing on multiple part types and rust conditions without dedicated fixtures.

Does YIHAI LASER offer rental of laser cleaning equipment?
Yes. YIHAI LASER offers rental programs for its laser cleaning systems, including on-site setup and operator training. Rental fees can be partially credited toward a purchase if the customer decides to buy the equipment after the trial.

References

1. YIHAI LASER, 500W Pulsed Fiber Laser Cleaning System Datasheet, 2026.
2. ISO 8501-1:2007, Preparation of steel substrates before application of paints and related products — Visual assessment of surface cleanliness.
3. ASME B46.1-2019, Surface Texture (Surface Roughness, Waviness, and Lay).
4. Momber, A.W., Hydroblasting and Coating of Steel Structures, Elsevier, 2003 (comparative surface preparation methods).
5. Cooper, M.G., “Laser Cleaning in Industrial Maintenance,” Journal of Laser Applications, Vol. 32, No. 2, 2020.

Read more:

What is the best Guide to laser Cleaning for beginners?

What are the disadvantages of laser Cleaning?

Beyond Rust: How to Use Laser Cleaning for Efficient Paint Removal