Enhancing the Quality and Sustainability of Laser Cutting Processes in Laser-Assisted Manufacturing Using a Box–Behnken Design

This study aims to examine and optimize CO2 laser cutting parameters—namely, laser power, cutting speed, and focal plane position—when applied to polypropylene material using an experimental methodology. This research aims to improve cutting quality, increase cutting speed, and reduce waste while adhering to sustainability objectives. To achieve these goals, a comprehensive experimental approach was employed, incorporating the Box–Behnken Design (BBD) based on the response surface methodology (RSM) to optimize the laser cutting process by evaluating the relationships between input parameters and output responses. Data were collected through a series of controlled experiments in which laser power (ranging from 30 to 60 W), cutting speed (ranging from 30 to 60 mm/s), and focal plane position (set at −3, 0, and +3 mm) were systematically varied. The responses, quantified regarding cut quality, include kerf width and the heat-affected zone (HAZ). Additionally, RSM was used to optimize the laser cutting process to improve kerf quality. The results indicated that cutting speed has an inverse effect on kerf width and HAZ, while laser power has a direct effect. Furthermore, the focal plane position was found to have the least impact on the output responses. The maximum kerf width and HAZ were observed at a minimum cutting speed of 30 mm/s and a maximum laser power of 60 W.