1:1 exchange, dispatched within 24 hours
An identical source comes from our stock and ships within 24 hours, subject to availability. Your old one is returned to us afterwards.
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CO2 laser tube and source refill
Your laser has lost power but the tube isn't broken? Then it's almost always the gas. We measure the real output, refill the source with the original mixture and send it back with a report showing the figures before and after, plus a 12-month warranty.
What actually wears out
It's the gas that tires, not the glass
The beam in a CO2 laser comes from a mix of carbon dioxide, nitrogen and helium, excited by high voltage. Every hour of running breaks down a little of the CO2, the mixture drifts out of balance and efficiency falls. The glass itself hardly ages at all.
- Jobs that used to take one pass now need two
- Scorched or ragged edges at the same speed as before
- Output that changes from one day to the next
- Hard to strike when cold, or a weak, flickering glow
So a drop in power almost never means the tube belongs in the bin. A tube that no longer gets through 4 mm plywood in one pass often still has 70 to 80 % of its rated power: plenty for engraving, not enough for cutting. A refill typically costs 30 to 50 % less than a new tube and brings back the original output.
Not sure? Have it measured. A power reading tells you within minutes whether the source is worth saving.
The refill, in full
More than topping up the gas
A proper refill is a sequence, not a squirt of gas. Your source is measured, opened, filled with the original gas mixture, sealed and measured again, and you get both readings in writing.
- Service report with before-and-after output and the electrical parameters
- Power reading on arrival
- Seal, electrodes and output mirror inspected
- Gas refill and sealing
- Second power reading and test run before packing
Refill timeline
What happens between dispatch and return
Your source's journey through the workshop, stage by stage. Tap a step for more detail.
Two different animals
Glass tube or RF source: why it matters
A DC-excited glass tube and a sealed RF metal source are refilled in different ways. In an RF source, the resonator and its drive electronics share one housing, so the power supply and driver need checking before anyone talks about gas.
- RF source: power supply, driver and cooling measured before it is opened
- Glass tube: electrodes, bellows and output mirror checked, then filled
- Seal tested under vacuum over several hours
- Output and beam profile recorded before it leaves
When the fault is in the electronics, no amount of gas will fix it, and we tell you so before you've spent a penny. You then get the diagnosis and, if you want one, a quote for the repair.
1:1 exchange
Sources on the shelf, ready to go
Refilling is only half of it: we also keep matching sources in stock. That gives you two routes, and your production schedule picks the route, not ours. Your old source comes back to our workshop afterwards, while your machine keeps working. If production has already stopped, a replacement source goes out at short notice, subject to availability, to keep the standstill as short as possible.
Refill: 3 to 7 working days
You get your own source back, measured before and after. The usual route when production can wait a week.
No price difference
An exchange costs no more than a refill, so the choice comes down to your schedule, not your budget.
Makes and models
Which sources we refill
From small engraver tubes to large-format cutting sources, we handle both DC-excited glass tubes and sealed RF metal sources.
Coherent Diamond, Iradion (154f, 156f, 1510f, 1512f, TL2 to TL8), Novanta / Synrad (48-2, T60, T80, T100, F201, F400), Rofin, Luxinar SR series, Eurolaser, Universal Laser Systems, Trotec Laser (Speedy), Epilog Laser (Fusion), Gravograph, GCC LaserPro, Rayjet, Cameo Laser, and others besides.
Model not listed? Send a photo of the rating plate. One reply tells you whether we can take it on and what the measurement would cost.
Pricing
€490 to €2,900 excl. VAT, depending on the source
That spread isn't vagueness. Refilling a small engraver tube and restoring a large RF cutting source are different jobs with different parts. So the price is set once we know the source, not before.
1. Tell us what you have
Manufacturer, model and condition. Those three details almost always tell us what kind of job it is.
2. We work out the scope
Is it a straightforward gas refill, or do the electronics and optics need work too? That's what moves the price.
3. You get a fixed price
Itemised and with no obligation, within 24 hours. We don't start until you've said yes.
Whatever the source, a refill comes in 30 to 50 % below the cost of a new tube, and we run that comparison with you before any work starts.
Get a price for my sourceYour checklist
Three things to send us first
What has changed
Gradual loss of power, uneven cutting, arcing, condensation: tell us what's different and since when.
A photo of the rating plate
Make, model and rated power of the source. One sharp photo is enough.
The tube length
Measured from one end of the glass to the other, without the mounts. It tells us the tube type.
On the bench
The same eight stages for every source
Every source goes through the same sequence here, and anything we tell you is backed by a measurement: residual gas is analysed with a mass spectrometer, and tightness is proven with a helium leak test and professional leak detection.
1. Incoming test and power reading
On the test bench we record what the source really puts out. That figure is the baseline and goes into your report.
2. Diagnosis
Residual gas analysis on the mass spectrometer shows the state of the mixture, so we know whether the power loss comes from the gas or from somewhere else.
3. Vacuum and leak check
Helium test and professional leak detection. A leaking source won't hold its fill, so any leak is dealt with before filling.
4. Filling
The original gas mixture goes in, in the right proportions and at a controlled pressure.
5. Resonator and optics
Mirrors, output mirror and resonator are checked, cleaned or replaced. Dirty optics would swallow exactly the power the refill has just restored.
6. RF and HF electronics
Power supply, driver and control go on the bench. With an RF source, the electronics matter as much as the gas.
7. Source alignment
We align the source until the beam and its profile are right. Only then does the power actually reach the workpiece.
8. Final reading
Back on the bench under the same conditions as on arrival. Two numbers on one sheet: before and after.
You receive a measurement report with the output before and after the refill and the electrical parameters, in black and white rather than on trust. Every properly completed refill comes with a 12-month warranty.
Refill FAQ
Straight answers about refilling
Could the power loss be something other than the tube?
Quite often, yes. A dirty mirror, a burnt lens or a beam that has drifted out of alignment produce the same symptoms. Clean the optics and check the alignment before you send anything; if you're still unsure, describe the whole machine to us.
Will I really get full power back?
On a source in good condition, yes, or very close to it. You don't have to take our word for it: you receive the measured output from before and after the refill.
What warranty comes with a refill?
12 months on every refill carried out to spec, documented in the service report together with the before-and-after measurement.
Is there a limit to how often a tube can be refilled?
The number of refills isn't the limit; the physical condition is. As long as the glass is intact and the electrodes aren't eroded, a tube can be refilled more than once. Our inspection tells you where yours stands.
What if my source turns out not to be refillable?
You'll hear it together with the measurement, before any work and before any refill invoice. Then it's your choice: a new replacement or a refurbished machine.
Which brands and models can you handle?
Almost every common CO2 system: Novanta / Synrad (48-2, T60, T80, T100, F201, F400), Iradion (154f, 156f, 1510f, 1512f, TL2, TL3, TL4, TL6, TL8), Coherent Diamond, Universal Laser Systems, Eurolaser, Luxinar SR series, Trotec Laser (Speedy), Epilog Laser (Fusion), Cameo Laser, Rayjet, Gravograph, GCC LaserPro, Rofin, and more. If in doubt, send a photo of the rating plate.
Related services
Keeping the rest of the machine up to scratch
A refilled source is only one part of a machine that runs reliably all year. Here's what else we do around the refill.
Servicing and repair
€89.50 per hour and €97.95 call-out, both excl. VAT, with service plans available. An annual check costs less than a breakdown halfway through a production run.
Talk to us about your machineSpare parts
Mirrors, lenses, nozzles, power supplies and belts for the makes we service ourselves. Give us the machine and part number and we'll check what's available.
See spare partsRefurbished used machines
Tube measured, optics checked, test cut before delivery, six-month warranty. Collect it from us or have it delivered; training is optional.
See machinesNeed a wear part or a machine right away? The spare parts shop and the refurbished machines are on our main site, laser-store24.de, along with our refill service page.
Everything for your CO2 laser from one workshop: back to the home page.
Losing power? Let's put a number on it.
Make, length, symptoms. We'll tell you whether a refill makes sense before you post anything.