Compact multi-process machines: why a 3-in-1 can change the economics of your shop

In SME metalworking companies, the difference between a profitable job and one that breaks even isn't just the arc or machine time. It's often the surrounding process that makes the difference: part handling, setup, waiting times between stations, micro-downtime, and rework. This is why compact machinery capable of performing multiple processes on a single platform is becoming an increasingly rational choice when the goal is ROI (return on investment) and process robustness .

In this article we look at the business case (with literature data) and then a concrete example: Freutek LMM0023, a 3-in-1 laser combination (welding, cleaning, cutting).  

1) The “invisible” cost: steps and equipment

Internal handling: it can weigh a lot

The handling of materials and semi-finished products is not a logistical detail: it is often a significant component of industrial costs. A scientific review of material handling systems reports that handling costs can represent a large share of the total production cost (ranges in the order of 15–70% ). (Amjath et al.) ( Springer Nature Link )

Practical translation in the workshop: every transfer between stations (moving, placing, picking up, realigning, cleaning, checking) accumulates minutes that add no value, but which you still pay for.

Setup and changes: the time reduction lever

If your shop operates in a high-mix/low-volume environment (large variety, small batches), frequent changeovers amplify the impact of setups. In the SMED (Single-Minute Exchange of Die) literature, you'll find case studies where the structured application of techniques leads to very significant improvements: one case published in IJAMT reported a 91.6% reduction in setup time . (Junior et al.) ( Springer Nature Link )

The key point: A “compact” multi-process machine does not eliminate the need for setups, but it can reduce the number of overall setups because it avoids re-setting and realigning the part on multiple machines/stations.

2) Why the laser platform is a natural candidate for multi-processing

High-energy beam processes (such as lasers) are considered “enabling” because they offer features not available with many conventional technologies and are transversal to multiple applications (joining, surface treatment, etc.). (Patterson et al.) ( Springer Nature Link )

On the cleaning/oxide removal front, the scientific literature describes laser cleaning as an efficient solution with a favorable environmental profile; for example, a work in Lasers in Manufacturing and Materials Processing defines it as “ efficient and environment-friendly ” for rust removal. (Narayanan, Singh, and Marla) ( Springer Nature Link )

In summary: a single laser platform can cover multiple “needs” typical of carpentry and sheet metal/metal workpiece processing: surface preparation, joining, and (on low thicknesses) cutting.

3) Concrete example: Freutek LMM0023 (3-in-1)

The LMM0023 is proposed as a 3-in-1 laser combination for:

• Laser welding
• Laser cleaning
• Laser cutting (for low thicknesses)

Technical data

• Power : 1500 W
• Cutting : cutting thickness up to 6 mm
• Compressed air : for cutting mode 1.0–1.5 MPa ; for welding 0.2–0.3 MPa .
• Cooling : distilled and deionized water .
• Intended use : Intended for thin-walled metallic materials and as a product sold in compliance with EU regulations.
• Dimensions and weight : approximately 1700 × 700 × 1600 mm and 250 kg .
• Price : starting from €7,650.00 (excluding VAT and shipping)

4) Micro-ROI scenario (hypothetical): when a 3-in-1 “pays for itself”

Below is a purely illustrative scenario (it is not a promise of results): it serves to understand the order of magnitude.

Assumptions (hypothetical)

• 20 jobs/week requiring cleaning + welding (and sometimes micro-cuts or finishing on low thicknesses).
• Traditional configuration: 2 medium transfers between stations + repositionings and checks.
• Estimated “non-value” time:
• Before : 40 min/work (movement + realignment + micro-waits)
• After (single platform): 13 min/work
• Savings : 27 min/work

Quick calculation

1. 27 min × 20 jobs = 540 min/week = 9 hours/week
2. Fully charged hourly rate (example): €35/hour
3. Savings: 9 × 35 = €315/week
4. Annualized (52 weeks): €16,380/year
5. Payback on €7,650 (price “starting from”): 7,650 / 16,380 = ~0.47 years , i.e. ~5–6 months

Robustness note: Even if the actual savings were only 3 hours/week , the payback would still be significant (about 17 months at €35/hour). The point isn't the precise number: it's the logic, i.e., reducing steps and setup .

5) When a compact multi-process machine makes more sense (checklist)

It typically makes sense when:

1. Workshop space is limited (and each additional station “costs” meters and more complex flows).
2. Highly variable work: many codes, small batches, emergencies.
3. You often have pre-cleaning or oxide/contaminant removal before welding (or restoration activities).

Want to reduce the risk associated with repetitive movements ? Musculoskeletal disorders are reported to be the most common work-related health problem in the EU, with economic impacts on businesses and society as well. (de Kok et al.)

Conclusion: an "economic" choice, rather than a technological one

A compact multi-process machine is not just a technological innovation: it is a direct response to three economic drivers typical of SMEs:

1. less handling ,
2. less duplicate CapEx ,
3. more work efficiency (fewer minutes “lost” between stations and setups).

If you'd like to check whether this approach makes sense for your workflow (materials, thicknesses, and order mix), visit the LMM0023 product page or fill out the contact form for a technical-application discussion.