Automatic bundle loading is usually the best solution for high-speed production of light round, square and rectangular tube. While much slower, stage loading is required for open profiles (C-channel, I-beam, etc.) and provides the weight capacity for large profile machines.
Unloading is equally important. High-speed machines allow for a controlled drop on the offload side, while large capacity machines utilize a chuck on the offload size to place parts onto an offload chain conveyor.
Automatic loading on a tube laser follows one of two forms: bundle loading and stage-loading.
Bundle Loading
At Fairmont, we strongly recommend bundle loading systems for high-speed laser cutting. As you can see in the video to the right, a bundle of identical tubes is placed into a cradle for the system to automatically separate and feed one bar at a time. This separation process and feeding process occurs while the previous tube is being cut, often referred to as occurring during “hidden time.”
Preparing to load the next tube while the laser cuts the current tube is essential on a high-speed tube laser. If your machine can cut an entire tube of nested parts in 60 seconds but it takes another 30 seconds to get the next tube into position, you have built a very fast laser that spends a third of its potential production time waiting for material.
Bundle loading comes with two major drawbacks. Bundle loaders cannot separate open profiles, like angles and C-channel. They also have a tube weight limit and a bundle weight limit.
Stage-Loading
Stage loading, also called chain loading or step loading, is a semi-automatic process. Individual tubes are laid onto steps, chains, or staging positions. The machine then feeds them automatically one at a time. The machine still loads the laser automatically, but the difficult job of separating one tube from a tangled bundle has already been solved. Stage loading is far more labor intensive but is more flexible than bundle loading and capable of supporting massive weights.
In large profile applications, stage-loading is a requirement. The chain-loading design can support massive weight – a requirement when processing structural beams.
In high speed production, stage-loading can handle the open profiles that are incompatible with bundle loading. In high-mix production, the operator can load a variety of material with corresponding programs in the control to produce a variety of parts at production speeds.
Offloading is often overlooked, but equally essential to tube and profile processing. The offload options are sorted into short parts and long parts.
Short parts are supported by a floating table at the end of the cutting process. After the part is cut, the floating table drops to a bin, sling or conveyor. Even large profile machines use some version of this process, as the chuck can only get so close to the cut line.
Long parts require support during the cutting process, either to lift significant weight or prevent bowing of the tube. On high-speed, two-chuck machines lasers – the floating table supports the weight of the part during cutting and drops the completed part into a bin after cutting.
On large parts, the third chuck moves to the unload side and works with the second chuck or an offload table to lower the part onto chain conveyor. While far slower, this process avoids free-dropping large and heavy tube.
Author: Alex Burnham, Senior Product Manager, Fairmont Machinery
Technical Review: Chip Burnham, Owner & CEO, Fairmont Machinery
Last updated: October 2026
