How to Validate a 3D Five-Axis Laser Cutting Machine Before Purchase: Sample Testing, FAT and Acceptance Criteria

A 3D five-axis laser cutting machine can look impressive in a brochure.

The specification may show:

• Large X/Y/Z travel
• High laser power
• Fast rotary axes
• Tight positioning accuracy
• Offline programming
• Automatic worktables

But none of these specifications alone proves that the machine can repeatedly process your actual part to the required quality and cycle time.

For complex applications such as:

• Hot-formed automotive components
• B-pillars
• Door rings
• Crossmembers
• Hydroformed tubes
• Curved sheet-metal components
• Aerospace parts
• Irregular 3D structures

the most useful validation method is to move from specifications to an actual application test.

A structured validation project should answer several questions:

1. Can the cutting head reach every required feature?
2. Can the fixture locate the part consistently?
3. Can the laser process produce the required edge and hole quality?
4. Can critical dimensions meet the drawing requirement?
5. Can the result be repeated across multiple parts?
6. Can the complete production cycle meet the required output?
7. Does the delivered machine match the configuration used during validation?

ZG Laser’s current five-axis project-evaluation process already recommends drawing review, process and fixture evaluation, machine configuration review and sample testing for critical projects.

The next step is to make that validation process measurable.

The key principle is:

One successful sample proves feasibility. Repeated samples begin to demonstrate repeatability. Production capability requires a separately defined validation plan.

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1. Why Sample Testing Matters Before Buying a Five-Axis Machine

A conventional sheet-metal cutting project can often be evaluated using well-established material and thickness data.

Three-dimensional cutting has more variables.

The result depends on:

• Part geometry
• Cutting-head orientation
• Machine travel
• Rotary-axis motion
• Fixture
• Workpiece variation
• TCP calibration
• Offline program
• Collision clearance
• Laser parameters
• Measurement method

A machine may have sufficient nominal travel but fail to reach one recessed hole.

It may cut a perfect contour on a rigid demonstration sample but struggle with a variable hot-formed production part.

It may produce acceptable dimensions while loaded in the fixture but fail after unclamping because the component relaxes.

This is why the actual application should be tested before a critical purchase is approved.

How to choose a 3D five-axis laser cutting machine

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2. Sample Testing, FAT and SAT Are Different

These three stages should not be mixed together.

Sample Testing

Usually occurs during application evaluation.

Its main purpose is to determine:

Can the proposed process manufacture the part?

It may happen before the final order.

FAT — Factory Acceptance Test

FAT takes place at the supplier’s factory before shipment.

Its purpose is to verify that the ordered equipment and agreed application requirements have been met before the machine leaves the supplier.

SAT — Site Acceptance Test

SAT takes place after installation at the customer’s factory.

Its purpose is to verify that:

• Installation
• Utilities
• Calibration
• Safety
• Production conditions

are correct at the final site.

Quick Comparison

Stage	Main Question
Sample Test	Can the proposed process make the part?
Repeated Sample Test	Can the process produce similar results repeatedly?
FAT	Does the completed machine meet the agreed pre-shipment requirements?
SAT	Does the installed machine operate correctly at the customer’s factory?

The exact scope should always be defined in the purchase agreement.

There is no single universal FAT checklist that applies to every custom five-axis laser project.

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3. What Should the Customer Provide Before Sample Testing?

The quality of the test depends heavily on the information supplied.

At minimum, provide:

Engineering Data

• 3D CAD model
• 2D drawing
• Drawing revision
• Part number
• Material grade
• Material thickness
• Coating, if applicable

Cutting Requirements

• Final trim lines
• Holes
• Slots
• Bevels
• Critical dimensions
• Edge-quality requirements

Production Requirements

• Annual volume
• Parts per shift
• Number of shifts
• Target cycle time
• Expected product variants
• Manual or automated loading

Quality Requirements

• Tolerances
• Inspection datums
• Inspection method
• Required reports

Physical Parts

For formed components, actual production samples are extremely valuable.

The nominal CAD model cannot fully show:

• Springback
• Surface variation
• Flange variation
• Weld distortion
• Real loading behavior

ZG Laser’s current project-evaluation page similarly asks buyers to provide drawings, material, thickness, maximum size, required accuracy and production capacity before a configuration is recommended.

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4. Use the Correct Drawing Revision

Before cutting anything, confirm:

Part CAD Revision = 2D Drawing Revision = Test Requirement

This sounds basic, but revision errors can invalidate an entire test.

A useful project record might contain:

Customer: ABC Automotive
Part Number: BP-RH-02
3D CAD Revision: F
2D Drawing Revision: F
Fixture Revision: B
NC Program Revision: P04
Test Date: 2026-xx-xx

If the drawing changes during the project, the old result should not automatically be treated as validation of the new revision.

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5. Test a Representative Production Part

Do not validate a machine using only a simple supplier demonstration sample.

A generic demo may prove that:

• The laser works
• The axes move
• The machine can perform 3D cutting

It does not prove that the machine can process your specific component.

A representative validation part should contain the important production challenges.

These may include:

• Long trim contours
• Small holes
• Recessed holes
• Angled surfaces
• Tight tolerance features
• Difficult fixture clearance
• Multiple cutting-head orientations

For hot-formed automotive projects, use production-representative formed components whenever possible.

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6. Test the Most Difficult Feature, Not the Easiest

Imagine a component contains:

• 20 simple holes
• 3 external trim contours
• 1 deeply recessed side-wall hole

The recessed hole should be one of the primary validation targets.

Similarly, identify:

• Smallest hole
• Tightest positional tolerance
• Maximum required head angle
• Deepest recess
• Longest cutting path
• Narrowest clamp clearance
• Most difficult trim transition

A machine that performs 95% of the geometry but cannot process one functionally critical feature is not a successful solution.

This principle is already included in ZG Laser’s current five-axis buyer guide: difficult access areas should drive feasibility testing rather than only easy external contours.

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7. Define Acceptance Criteria Before Cutting

Do not perform the test first and decide afterward what counts as acceptable.

Before sample cutting, both sides should agree on measurable criteria.

Examples include:

Geometry

• Hole position
• Hole diameter
• Slot size
• Trim-line position
• Feature-to-feature distance

Cutting Quality

• Complete cut
• Dross
• Edge appearance
• Taper
• Oxidation
• Local heat damage

Production

• Complete cycle time
• Loading method
• Operator intervention
• Alarm frequency during test

Repeatability

• Number of repeated parts
• Features to be measured
• Acceptable part-to-part variation

The important principle is:

Acceptance criteria should be agreed before the results are known.

This protects both buyer and supplier.

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8. Separate Critical Features From General Features

Not every dimension needs the same acceptance priority.

Identify:

Critical-to-Function Features

Examples:

• Assembly locating holes
• Mounting holes
• Weld interfaces
• Datum-related trims

General Features

Examples:

• Clearance openings
• Non-functional trim edges
• Scrap contours

This helps prevent a test from focusing heavily on an easy cosmetic edge while ignoring a critical hole position.

A useful FAT drawing can visually mark critical features.

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9. Agree on the Measurement Datum

A dimension has meaning only relative to its defined datum system.

Before testing, agree on:

• Primary datum
• Secondary datum
• Tertiary datum
• Measurement coordinate system

The manufacturing fixture and inspection process do not necessarily need to be identical, but their datum relationship must be clearly understood.

Renishaw’s process-setting guidance similarly emphasizes establishing the relationship between machine, part and coordinate system through datum features before production begins.

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10. Define Free-State vs Constrained Measurement

This is particularly important for formed sheet-metal parts.

A component may be measured:

• Freely supported
• On a checking fixture
• On the laser cutting fixture
• Under defined clamping conditions

The result can differ.

Example

A thin formed panel may meet dimensional requirements while constrained by the cutting fixture but move slightly after unclamping.

This does not automatically indicate a machine problem.

The drawing and customer quality standard should define the required inspection state.

Do not wait until FAT to discover that:

Supplier measured on fixture

while:

Customer expected free-state measurement.

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11. Agree on the Inspection Equipment

Possible measurement methods include:

• Calipers
• Height gauges
• Go/no-go gauges
• Functional gauges
• Checking fixtures
• CMM
• 3D scanning
• Vision systems

Choose the method according to:

• Tolerance
• Geometry
• Feature accessibility
• Customer quality procedure

For tight dimensional criteria, the measuring method itself must be sufficiently capable and properly calibrated.

Do not claim machine failure from measurement data whose uncertainty is too large for the tolerance being evaluated.

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12. Validate the Fixture Before Judging the Machine

A poor fixture can make a good machine appear inaccurate.

Before evaluating cut dimensions, verify:

• Correct datum strategy
• Locator condition
• Fixture installation
• Clamp sequence
• Clamp force
• Part seating
• Fixture repeatability

The fixture should locate the component consistently without forcing it into an artificial geometry.

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13. Perform a Repeat-Loading Test

Before cutting several production samples, it can be useful to test the fixture itself.

A simple method is:

1. Load the same component.
2. Clamp it.
3. Measure selected reference positions.
4. Unload it.
5. Reload the same component.
6. Repeat.

This helps separate:

Fixture loading variation

from:

Part-to-part incoming variation.

If the same component does not return to the same position consistently, cutting more samples will not solve the underlying fixture problem.

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14. Verify Cutting-Head Accessibility

The sample test should confirm that the complete laser head can reach every feature.

Check:

• Nozzle clearance
• Head-body clearance
• Clamp clearance
• Rotary-axis range
• Lead-in motion
• Lead-out motion
• Rapid repositioning
• Deep feature access

A successful offline simulation is very valuable, but the real fixture and machine should still be verified before full-speed production.

Offline programming and collision simulation

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15. Record the Exact Machine Configuration Used for Testing

This is essential.

The validation record should identify:

• Machine model
• Machine serial number, if available
• Laser source
• Laser power
• Cutting head
• CNC/control
• Worktable configuration
• Software
• Fixture
• Assist-gas system

Why?

Imagine a sample is tested successfully using:

6000W + production rotary table + one head configuration

but the commercial quotation later specifies:

3000W + different table + different cutting head

The original result should not automatically be considered proof of the quoted configuration.

A sample test validates a specific process configuration.

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16. Record Process Parameters

Important parameters can include:

• Laser power
• Cutting speed
• Focus
• Assist gas
• Gas pressure
• Nozzle
• Stand-off distance
• Piercing parameters
• Cutting direction
• Head orientation

This creates a process record.

Without these details, a successful sample may be difficult to reproduce later during FAT or SAT.

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17. Record the Fixture Revision

Fixtures often change during development.

For example:

Rev A

→ clamp interferes with cutting head.

Rev B

→ clamp moved.

Rev C

→ new support added to improve repeatability.

The test report should therefore identify the fixture revision used.

Otherwise, a later FAT may unknowingly use a modified fixture and be compared with results produced under different conditions.

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18. Record the NC Program Revision

The same principle applies to programming.

A production record should contain:

• Part revision
• Fixture revision
• NC program revision
• Parameter revision

This is particularly important after:

• Collision-clearance modifications
• Cycle-time optimization
• Kerf compensation changes
• Coordinate corrections

A useful production rule is:

Approved part + approved fixture + approved program + approved parameters = validated process configuration.

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19. Measure Complete Cycle Time

Do not validate productivity using laser-on time alone.

Record:

Total Cycle Time = Loading + Positioning + Clamping + Table Movement + Piercing + Cutting + Repositioning + Unclamping + Unloading

For rotary-table production, also determine whether loading can occur in parallel with cutting.

Separate the Major Time Components

For example:

Stage	Time
Loading	—
Clamping	—
Table indexing	—
Cutting	—
Unclamping	—
Unloading	—
Total cycle	—

Do not enter hypothetical values in the published article; use the real project data during validation.

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20. Record Operator Intervention

A sample may look successful while requiring constant manual assistance.

Record whether the operator needed to:

• Reposition the part
• Clear scrap
• Reset alarms
• Modify the program
• Manually adjust the fixture
• Clean the nozzle
• Stop the machine

A production process requiring repeated intervention may not achieve the same throughput as an ideal demonstration cycle.

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21. One Successful Sample Proves Feasibility

A single successful sample answers an important question:

Can this machine and process manufacture the part under these conditions?

That is valuable.

But it does not prove:

• Long-term repeatability
• Process capability
• Shift-to-shift stability
• Fixture durability

Therefore, describe one part correctly:

Feasibility sample

rather than:

Mass-production capability proof.

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22. Repeated Parts Begin to Evaluate Repeatability

The next step is to process multiple components using the same approved conditions.

Measure the same critical features on each part.

Record:

• Hole position
• Trim position
• Key dimensions
• Edge condition
• Cycle time

This allows you to see whether results are:

• Stable
• Drifting
• Randomly varying

Important

A small group of consecutive samples can provide useful repeatability evidence.

It should not automatically be presented as a formal statistical process-capability study.

If Cp, Cpk, Pp, Ppk or another capability metric is contractually required, define:

• Sample quantity
• Sampling period
• Measurement method
• Production conditions
• Calculation method
• Acceptance value

before the study begins.

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23. Distinguish Machine Repeatability From Production Repeatability

Part-to-part variation can come from several sources.

Conceptually:

Production Variation = Machine + Calibration + Fixture + Incoming Part + Laser Process + Measurement

For example, if hole position varies between samples, possible causes include:

• Fixture loading
• Formed-part variation
• TCP calibration
• Coordinate system
• Measurement variation

Do not immediately conclude that every variation is machine-axis error.

What determines 3D five-axis laser cutting accuracy

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24. Create a Sample Validation Record

A structured report may include:

Item	Record
Customer	Project name
Part	Part number
Drawing	Revision
CAD	Revision
Material	Grade
Thickness	Actual
Machine	Model
Laser	Source / power
Cutting head	Model/configuration
Fixture	Revision
NC program	Revision
Assist gas	Type
Test part	Sample ID
Cycle time	Complete cycle
Inspection method	CMM / gauge / etc.
Measurement result	Recorded values
Edge quality	Result
Operator intervention	Record
Deviations	Record

This report becomes useful later during FAT.

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25. What Is a Factory Acceptance Test?

A Factory Acceptance Test, or FAT, is performed at the supplier’s facility before shipment.

For a custom five-axis laser project, FAT should normally verify two levels.

Level 1 — Machine-Level Acceptance

Does the delivered machine match the ordered configuration and operate correctly?

Level 2 — Application-Level Acceptance

Can the completed system execute the agreed customer process?

This distinction matters.

A machine can pass a mechanical FAT while still failing the customer’s application requirement.

For application-specific equipment, both levels should be considered in the acceptance agreement.

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26. Machine-Level FAT

Typical machine-level FAT items may include:

Configuration

• Correct machine model
• Correct axis travel
• Correct laser source
• Correct laser power
• Correct cutting head
• Correct worktable

Machine Function

• Axis operation
• Rotary-axis operation
• Worktable operation
• Laser operation
• CNC/control

Safety

• Door interlocks
• Emergency stops
• Enclosure
• Safety functions

Supporting Systems

• Dust extraction interface
• Gas system
• Cooling
• Pneumatics
• Electrical cabinet

Software

• Offline programming package
• Postprocessor
• Machine configuration
• Licenses

The exact list should match the signed technical agreement.

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27. Application-Level FAT

For a customized 3D cutting project, this is often the more valuable section.

Possible acceptance items include:

• Correct customer part
• Correct fixture revision
• Approved NC program
• Approved process parameters
• Head accessibility
• Cutting quality
• Critical dimensions
• Repeated sample results
• Complete cycle time
• Loading/unloading method

The customer and supplier should agree which items are binding acceptance criteria and which are engineering observations.

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28. Suggested Five-Axis FAT Checklist

Machine Configuration

☐ Machine model confirmed
☐ Laser power confirmed
☐ Cutting head confirmed
☐ Axis travel confirmed
☐ Rotary axes confirmed
☐ Worktable confirmed

Safety & Utilities

☐ Safety doors/interlocks tested
☐ Emergency stop tested
☐ Cooling system checked
☐ Gas system checked
☐ Extraction interface checked

Software

☐ Offline software confirmed
☐ Machine model confirmed
☐ Postprocessor confirmed
☐ NC program transfer tested
☐ Collision simulation workflow verified

Fixture

☐ Correct fixture revision
☐ Fixture installation verified
☐ Datums checked
☐ Clamp operation tested
☐ Part loading tested

Application

☐ Correct drawing revision
☐ Correct material
☐ Critical features processed
☐ Cutting quality inspected
☐ Dimensions measured

Production

☐ Complete cycle measured
☐ Repeated samples performed as agreed
☐ Operator intervention recorded
☐ Scrap handling reviewed

Documentation

☐ Test report
☐ Measurement report
☐ Machine configuration list
☐ Software information
☐ Training documentation
☐ Maintenance documentation

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29. The FAT Checklist Should Be Project-Specific

Do not copy an online FAT template and assume it is sufficient.

A B-pillar production line and a prototype aerospace cell may require very different acceptance tests.

The checklist should reflect:

• Contract
• Part
• Production volume
• Automation
• Quality requirement
• Destination

If the project does not require a particular test, do not create unnecessary acceptance risk.

If a requirement is critical, make sure it is written into the agreement before machine completion.

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30. What Should Be in the FAT Report?

A professional FAT record can contain:

Machine Identification

• Manufacturer
• Model
• Serial number
• Laser source
• Power

Project Identification

• Customer
• Part number
• Drawing revision

Production Configuration

• Fixture revision
• NC revision
• Parameter revision

Test Conditions

• Material
• Thickness
• Gas
• Inspection method

Results

• Critical dimensions
• Cutting-quality observations
• Cycle time
• Repeated-part results

Deviations

• Open items
• Corrective actions
• Re-test requirement

Sign-Off

• Supplier
• Customer or authorized representative
• Date

Photographs or video may also be included where appropriate.

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31. FAT Should Verify the Configuration That Will Be Shipped

This is critical.

The system tested during FAT should correspond to the system being delivered.

If a temporary component is used during testing, document it.

Examples:

• Different laser source
• Temporary fixture
• Prototype cutting head
• Alternative software license

The buyer should know whether the FAT result represents:

final delivery configuration

or:

temporary engineering configuration.

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32. What Happens If the Sample Fails?

A failed test does not automatically mean the entire machine concept is wrong.

Classify the problem first.

Geometry Failure

Examples:

• Hole offset
• Trim shift

Check:

• Datum
• Fixture
• Coordinate system
• TCP
• Calibration
• NC program

Edge-Quality Failure

Examples:

• Dross
• Rough edge
• Incomplete cut

Check:

• Laser power
• Focus
• Speed
• Assist gas
• Nozzle

Collision or Accessibility Failure

Check:

• Head orientation
• Fixture
• Clamp
• Machine envelope
• Offline program

Cycle-Time Failure

Check:

• Cutting sequence
• Laser power
• Rotary movement
• Table architecture
• Loading process

Repeatability Failure

Check:

• Fixture loading
• Incoming-part variation
• Machine condition
• Measurement system

A structured root-cause investigation is more useful than random parameter adjustment.

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33. Do Not Hide a Failure by Changing the Acceptance Criterion

Suppose the agreed hole-position requirement is X.

After testing, the result does not meet X.

The wrong response is:

“Maybe X was too strict; let’s call this acceptable.”

unless the customer engineering team formally changes the requirement.

Likewise, the buyer should not introduce a previously undisclosed tighter requirement only after seeing successful results.

The fair principle is:

Agree first. Test second. Judge against the agreed criteria.

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34. Supplier Demo Sample vs Customer Production Sample

These two samples serve different purposes.

Supplier Demo Sample

Useful for showing:

• Machine movement
• General cutting ability
• Surface quality
• Complex geometry

It is primarily a capability demonstration.

Customer Production Sample

Useful for evaluating:

• Actual geometry
• Actual tolerances
• Fixture
• Cycle time
• Production feasibility

For equipment purchasing, the second is much more valuable.

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35. What About Remote FAT?

Remote FAT can be practical when:

• Travel is difficult
• The project is relatively standardized
• Acceptance items can be documented clearly

A remote FAT package may include:

• Live video
• Recorded cycle
• Machine configuration photographs
• Measurement report
• Sample photographs
• Test files
• Finished samples shipped to the customer

Improve Remote FAT Credibility

Show:

• Part identification
• Drawing revision
• Machine identification
• Continuous cycle where relevant
• Measuring equipment
• Actual measurement values

Avoid relying only on edited promotional video.

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36. When Is On-Site FAT at the Supplier More Valuable?

Customer attendance at the supplier’s factory deserves consideration for:

• High-value equipment
• Custom fixtures
• Automotive production cells
• Strict cycle-time requirements
• Critical dimensional projects
• New process development

Being physically present can make it easier to review:

• Machine configuration
• Loading
• Cutting
• Measurement
• Software
• Training

But attendance should be decided according to project risk rather than treated as mandatory for every machine.

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37. FAT Is Not the End: The Machine Still Needs SAT

After FAT approval, the machine is:

• Disassembled where necessary
• Packed
• Transported
• Installed again

The final factory introduces different:

• Foundation
• Temperature
• Electricity
• Gas supply
• Compressed air
• Extraction
• Network
• Operator environment

Therefore, final site verification is still important.

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38. What Is a Site Acceptance Test?

SAT verifies the installed system at the customer’s factory.

Typical SAT areas include:

Installation

• Machine location
• Leveling
• Mechanical installation
• Electrical installation

Utilities

• Electrical supply
• Assist gas
• Compressed air
• Cooling
• Extraction

Machine Condition

• Calibration
• Axis operation
• Safety

Application

• Fixture installation
• NC program
• Part cutting
• Dimensional verification

Training

• Operator
• Programmer
• Maintenance personnel

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39. FAT vs SAT

FAT	SAT
Supplier factory	Customer factory
Before shipment	After installation
Supplier utilities	Customer utilities
Confirms ordered machine	Confirms installed machine
Application test under supplier conditions	Application test under real site conditions
Pre-shipment acceptance	Final site acceptance

The exact commercial meaning of FAT and SAT should be defined in the contract.

Do not assume that the terminology automatically creates the same obligations in every purchase agreement.

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40. Why Calibration Should Be Checked After Installation

The relationship between:

• Linear axes
• Rotary axes
• Cutting head
• Fixture
• Coordinate system

must remain correct.

Transport and installation are therefore followed by machine setup and verification.

Renishaw’s process-control guidance emphasizes establishing machine, fixture, rotary-axis and workpiece relationships before machining, while its broader process-control framework separates process setting from post-process inspection.

For a five-axis laser system, follow the machine manufacturer’s installation and calibration procedure rather than simply copying the supplier-factory offsets.

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41. Verify the Customer’s Utilities During SAT

A process validated during FAT can behave differently if the customer’s utilities are insufficient.

Check:

Assist Gas

• Type
• Pressure
• Flow
• Purity where specified

Compressed Air

• Pressure
• Flow
• Dryness
• Filtration

Electricity

• Voltage
• Capacity
• Stability

Extraction

• Airflow
• Ducting
• Filter installation

Environmental Conditions

Where relevant:

• Temperature
• Humidity
• Dust

These factors belong to the complete production system.

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42. Compare FAT and SAT Results

For the agreed validation part, compare:

• Critical dimensions
• Cutting quality
• Complete cycle time
• Machine behavior

The goal is not necessarily to reproduce every microscopic measurement identically.

The goal is to confirm that the installed process meets the agreed acceptance requirement.

If results differ materially, investigate:

• Calibration
• Fixture installation
• Utilities
• Parameters
• Material batch
• Measurement method

before changing the acceptance criteria.

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43. Digital Simulation Supports Validation—but Does Not Replace It

Offline simulation can significantly reduce machine-side prove-out.

Modern CNC digital-twin systems can model:

• Machine kinematics
• Workpiece
• Fixture
• Tooling
• NC execution

and detect potential collisions before production. Siemens’ current Run MyVirtual Machine and NX machine-simulation solutions specifically support complete machine models, NC validation, collision detection and realistic cycle-time calculation.

This is extremely valuable.

But simulation cannot fully reproduce every physical condition, including:

• Incoming-part variation
• Fixture contamination
• Flexible scrap
• Clamping deformation
• Gas behavior

Therefore:

Virtual validation reduces physical risk; physical validation confirms the real process.

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44. A Complete Validation Workflow

A strong project can follow this sequence:

Customer Drawing
↓
Application Review
↓
Machine Configuration
↓
Fixture Concept
↓
Offline Programming
↓
Collision Simulation
↓
Sample Cutting
↓
Dimensional Inspection
↓
Repeated Samples
↓
Configuration Approval
↓
Machine Manufacturing
↓
FAT
↓
Shipment
↓
Installation & Calibration
↓
SAT
↓
Production Training
↓
Production Release

This is much more reliable than:

Buy machine → ship machine → see whether the part works.

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45. Recommended Acceptance Criteria Categories

A practical technical agreement can organize acceptance into six areas.

1. Machine

• Configuration
• Working range
• Functions

2. Safety

• Interlocks
• Emergency functions
• Enclosure

3. Software

• Programming
• Postprocessor
• Simulation

4. Application

• Part
• Fixture
• Cutting geometry

5. Quality

• Critical dimensions
• Edge requirements
• Repeatability

6. Productivity

• Complete cycle time
• Loading strategy
• Operator intervention

This structure helps prevent important requirements from being buried inside a long machine specification sheet.

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46. Do Not Use Vague Acceptance Language

Avoid contractual statements such as:

“Good cutting quality.”

“High accuracy.”

“Fast production.”

These are difficult to verify.

Where commercially necessary, replace them with agreed measurable criteria such as:

• Drawing-defined dimensional tolerance
• Agreed inspection method
• Agreed complete cycle-time method
• Agreed acceptable edge condition

Use photographs or approved reference samples if visual criteria are difficult to describe numerically.

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47. Cycle-Time Acceptance Must Define the Starting and Ending Point

A claimed 90-second cycle can mean very different things.

Does the clock start when:

• The operator touches the part?
• Clamping finishes?
• Laser turns on?

Does it stop when:

• Laser turns off?
• Table returns?
• Finished part is removed?

For meaningful comparison, define:

Cycle Start

and:

Cycle End

before FAT.

For example:

From start of loading of one production part to the point at which the machine is ready to begin the next equivalent cycle.

The exact definition should reflect the customer’s production system.

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48. Define Whether Manual Actions Are Included

If cycle acceptance is important, document:

• Number of operators
• Manual loading
• Manual scrap removal
• Manual inspection
• Manual nozzle cleaning

Otherwise, two tests can claim the same machine cycle while using very different labor.

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49. What Information Should the Buyer Receive After Validation?

For an application-specific project, useful handover information may include:

• Approved machine configuration
• Approved fixture revision
• Approved NC program
• Approved parameter set
• FAT report
• Measurement report
• Training documents
• Maintenance guidance
• Software/license information
• Backup files

Not every project requires every document, but the scope should be agreed before shipment.

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50. Final Pre-Purchase Validation Checklist

Before approving a critical five-axis project, confirm:

Part

• Correct CAD revision
• Correct drawing revision
• Actual material tested
• Representative sample used
• Difficult features included

Acceptance

• Critical dimensions agreed
• Datum system agreed
• Measurement state agreed
• Inspection equipment agreed
• Cutting-quality criteria agreed
• Cycle-time definition agreed

Fixture

• Fixture concept verified
• Repeat-loading checked
• Clamp deformation reviewed
• Cutting-head clearance verified

Machine

• Exact test configuration recorded
• Laser power recorded
• Cutting head recorded
• Worktable recorded

Programming

• NC revision recorded
• Fixture revision recorded
• Collision simulation completed
• Process parameters recorded

Validation

• Feasibility sample completed
• Repeated samples completed if required
• Results documented
• Deviations closed or accepted

FAT

• Machine FAT scope agreed
• Application FAT scope agreed
• Documentation scope agreed
• Witness method agreed

SAT

• Installation scope agreed
• Utility requirements confirmed
• Calibration procedure defined
• Site test criteria defined

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Conclusion

A five-axis laser cutting machine should not be validated by a brochure specification or one attractive demonstration video.

The strongest purchasing decision is based on a structured sequence of:

representative sample testing → dimensional inspection → repeated verification → FAT → SAT

Each stage answers a different question.

A single sample answers:

Can the process make the part?

Repeated parts begin to answer:

Can the process produce similar results consistently?

FAT answers:

Does the completed machine match the agreed pre-shipment machine and application requirements?

SAT answers:

Does the installed system perform correctly under the customer’s real factory conditions?

The most important rule is to define acceptance criteria before the test begins.

That includes:

• Drawing revision
• Critical dimensions
• Datums
• Measurement method
• Fixture
• Machine configuration
• Cycle-time method
• Number of validation parts

A successful five-axis purchase is therefore not only about selecting the right machine.

It is about creating an agreed and traceable path from:

customer drawing

to:

validated production process.

Validate Your 3D Part Before Ordering a Five-Axis Machine

Send ZG Laser:

• Your 3D CAD model
• 2D drawing
• Actual formed sample
• Material and thickness
• Critical dimensions
• Required tolerances
• Annual production volume
• Target cycle time

Our application team can evaluate:

• Cutting-head accessibility
• Machine configuration
• Fixture requirements
• Offline programming
• Sample-testing strategy
• Inspection requirements

before the final machine configuration is approved.

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Frequently Asked Questions

Should I request sample cutting before buying a five-axis laser machine?

For critical or custom 3D applications, sample testing is strongly recommended because it can verify cutting-head accessibility, fixture strategy, dimensional results, edge quality and production feasibility on the actual part.

Is one successful sample enough to approve a machine?

It can demonstrate feasibility, but it does not by itself prove repeated production stability. Repeated parts should be evaluated when repeatability is important.

How many samples should be tested?

There is no universal number for every project. The quantity should be defined according to production risk, tolerance, volume and the purpose of the test. A formal process-capability study requires a separately defined statistical plan.

What should be measured during a five-axis sample test?

Typical items include critical hole positions, hole sizes, trim-line locations, slots, edge condition and complete cycle time. The exact criteria should come from the customer’s drawing and production requirements.

What is FAT for a laser cutting machine?

FAT means Factory Acceptance Test. It is normally performed at the supplier’s factory before shipment to verify the agreed machine configuration, operation and, where specified, the customer’s application requirements.

Is FAT the same as sample testing?

No. Sample testing often occurs during process and equipment evaluation. FAT normally verifies the completed ordered machine before shipment.

What is SAT?

SAT means Site Acceptance Test. It is performed after installation at the customer’s factory to verify machine installation, utilities, calibration and agreed production requirements under real site conditions.

Should FAT include actual customer parts?

For an application-specific five-axis project, including the agreed customer part can make FAT much more meaningful because machine operation alone does not prove the production application.

Should cycle time be part of FAT?

If cycle time is an important purchasing requirement, it should be explicitly defined in the technical agreement, including what actions are included in the measured cycle.

Why must the measurement datum be agreed before testing?

Because the reported feature position depends on its datum system. Different inspection references can produce different interpretations of the same component.

Can a part pass while clamped but fail after it is removed?

Yes. Flexible or formed components may change shape after unclamping. The required inspection state should therefore be defined before acceptance testing.

Does offline collision simulation eliminate the need for a physical first test?

No. Digital simulation can substantially reduce collision and programming risk, but physical validation is still needed to account for real fixtures, incoming-part variation, process behavior and other physical conditions.

What if the FAT sample fails?

First identify whether the problem relates to geometry, fixture, calibration, cutting parameters, collision/accessibility, cycle time or incoming-part variation. Correct the root cause and repeat the agreed test where necessary.

Should the machine tested during FAT be the exact machine shipped?

The FAT should clearly identify the machine and configuration being accepted. Any temporary or substitute component used during testing should be documented.

What should be included in the final FAT report?

Depending on the project, it can include machine identification, customer part revision, fixture revision, NC program revision, test conditions, measurement results, cycle time, deviations, corrective actions and sign-off.