The food industry has long been experimenting the use of thermoplastics for food packaging. Materials such as polyester are easy  to  manipulate and inexpensive. Plus, the fact that they are sterile, strong and waterproof make them ideal for the packaging of fresh or ready to use food products.

In this article we will discuss how to seal plastic containers using a CO2 laser scanning process. This technique can substitute the traditional mechanical application based of heat and pressure. It becomes possible to notably speed up the sealing process, increase its flexibility and reduce the consumption of resources.

The packaging of food products

Traditionally, food containers are sealed by applying heat and pressure to a thermoplastic sheet. The machines used for this process are very bulky and require strong fixturing of the containers to be processed. They have to be kept perfectly still while the sealing head applies pressure and heat to the plastic film in order to seal the container.

This process has some limitations. Since it is above all a mechanical process, the parts that come into contact with each other get worn with time and have to be replaced. The tools have to be tailor-made to adapt to each type of container which makes the production line hard to change quickly. These types of machines require constant cleaning and maintenance. Finally, one needs to consider the cost of stocking and upkeeping the various pieces of machinery.

Nowadays, this type of production is hard to sustain. Flexibility and speed of execution are determining factors that will allow a company to promptly take on the changing requests of the market. The CO2 laser sealing makes it possible to overcome the previously mentioned inconveniences as well as seal plastic containers in a fast and flexible way.

How does laser sealing of food containers work?

In a laser sealing process, productivity is key. A high powered laser source that works in tandem with a highly performing laser scanning head allows for high production rates. The laser source produces the beam that generates the necessary energy and heat to seal the thermoplastic sheet to the container. The higher the power of the laser source, the shorter the production cycle.

A scanning head directs the CO2 laser exactly where needed. A highly performing laser scanning head has galvanometer mirrors with very high angular velocity, that ensure an instant response and therefore a fast production process.

Thanks to this system, the laser doesn’t only do welding: the same source can be used to finish off the product, for example, cutting off the parts that exceed the size of the container.

This process is very versatile and suitable for every type of container. It is particularly useful for multi-compartment containers. As opposed to mechanical processes, laser welding is contactless and therefore a completely sterile process which makes it perfect for the food industry. There are no costs related to maintenance or the deterioration of tools and it isn’t necessary to change any machinery pieces for different production runs. The process is fully computerised and the change of production is practically instantaneous.

In conclusion, the use of the CO2 laser for the sealing of food containers is a fast and flexible process. It makes it possible to take full advantage of the company’s resources.

The fashion industry is always looking for new ideas and new technology to make them possible. Laser has become an incredible tool for stylist and designers, enabling them bring even the most technically difficult ideas to light. The pioneer designers who made the first use of laser, often went on to become famous in the fashion world.

It is a known fact that originality takes the win in fashion.

Laser technology has changed the way fashion is designed and produced. Now, like most other sectors, textile manufacturers can use the techniques of digital production: fast prototyping, small scale productions, and the possibility to produce on demand.

When some processes could only be made by an experienced artisan, with laser cutting, they can now be made almost instantaneously and in a perfectly uniform and precise way.

Laser cutting for textiles in fashion

There are many materials used in fashion, most of which can be cut by laser. Though fabric is still the most popular material, acrylic polymers (used for fashion accessories and shoe making) is also commonly used by the fashion industry.

Here is a list of the most common materials that can be cut by laser:

• fabric of natural or plant origin
• wool
• cotton
• linen
• synthetic fabric
• polyester
• nylon
• elastan
• fabric of animal origin
• leather
• silk
• acrylic plastic
• PMMA
• wood
• lace and crochet
• thin metal decorations

The process

The laser beam is concentrated on a specific area of the material until it provoques immediate evaporation. This process, called sublimation, is instantaneous and produces precise and clean cuts.

Other effects can be obtained by varying the laser’s speed. Indeed, laser cutting isn’t the only possible operation. By using the same laser, one can obtain marking effects for decoration.

The process is contactless so there is no risk of leaving unwanted traces on the material. This is particularly advantageous for delicate materials such as silk. This characteristic makes it possible to decrease or even eliminate wear and accidental damage during production, guaranteeing a better end product for sales.

The right technology to use

CO2 laser is by far the most popular in the fashion industry. It is powerful and versatile, and its wavelength is compatible with all the materials used in this field.

A laser system optimized for fabric cutting includes a CO2 laser source and a scanning head. Both are controlled by a software that manages their parameters according to the intended result.

The laser source’s job is to generate a laser beam. The types of laser power available range from low power CO2 lasers like El.En.’s RF88, to high power ones like El.En.’s Blade RF888. The choice of laser power will depend on what kind of production system the CO2 laser is inserted in: the higher the power, the faster the production will be.

The scanning head’s job is to concentrate the laser on the surface and move it along the desired path.

The software is the ‘brain’ of the system: it translates the information contained in vector file produced by the designer in impulses for the scanning head and laser source.

The main advantage of such a system is that it can be completely automated: it can be integrated in pre-existing productive systems or take part in a system made especially for laser cutting.

Do you want a tailor-made application?

As previously explained, laser technology has a wide range of applications. The best way to know which application is right for you, and find the ideal configuration, is to talk to an expert. Send us an email to explain your requirements and we will find the best solution for you.

Glass is one of the many materials that can undergo CO2 laser treatments. Laser is most often used for markings or cuts. In this article, we will explore how compatible glass is with laser technology and its possible applications.

Glass composition

Glass is a material of natural origin, composed mostly of silica (SiO2). The material is heated until it reaches melting point and then left to resolidify. This process yields glass, a transparent material with a great resistance to corrosion.

Glass does have some defects, though. It is fragile and has a low resistance to thermal expansion.

Types of laserable glass

It is important to take its negative characteristics into consideration before applying laser technology to glass. Its type of composition and production will be deciding factors when choosing where to use laser.

Composition

Most of the glass available on the market isn’t composed solely of silica. Depending on the glass’ final use, other components are added to the silica to modify the material’s properties.

Adding substances to the material does alter its ‘laserability’. For example, laser technology cannot be used when metal has been added to glass. Crystal is part of this category of glass. In order to increase transparency, lead is added to the composition, thus making it incompatible with laser.

Production

Most glass is produced industrially. Nonetheless, one can still find productions of artisanal glass objects; obviously at a higher price.

The first type of glass has a more uniform structure which makes it a better candidate for laser applications. Artisanal glass, on the other hand, isn’t as easy to use with laser. The glass can contain structural and compositional inconsistencies like microfractures. This glass could easily crack when exposed to the heat generated by the laser.

How laser technology works on glass

Though laser applications usually work by sublimation for most materials, in the case of glass, the process is different. As previously mentioned, glass has a low tolerance for thermal expansion. Laser technology takes advantage of this characteristic by generating fractures at a microscopic level. These result in markings or cuts.

How does this process take place? Glass contains trapped microbubbles of air. When the laser touches upon the surface, it heats it and causes the dilatation of these bubbles. Due to the material’s lack of flexibility, this dilatation generates the aforementioned micro-fractures.

CO2 laser markings on glass

Laser marking is the most common technique applied to glass. It is usually used for decorations or the marking of codes and other information.

Productions using laser have many advantages compared to traditional methods. They are cleaner, cheaper and offer a much wider range of applications.

Markings can be done in different ways, depending on the type of glass.

Soda glass

Soda glass is the most common form of glass. It is used for windows, bottles, glass flatware and other commonly used glass objects. It works well with laser technology.

On this type of glass, markings are made by generating thousands of microfractures on the glass’s surface. Thermal shock causes the dilatation of the glass, which, due to its rigid nature, fractures at a microscopic level. The final result is an opaque marking with a satin finish. It looks very similar to results obtained using more traditional methods, but at a much lower price.

Examples of this process can be found in the decoration field (decoration of glasses and flatware, windows and cabinets), in the car industry (identifying codes markings on car windshields and windows), in the production of glassware for laboratories (measurement markings).

Quartz glass

Quartz glass is obtained from the fusion of quartz rather than silica. It has a high resistance to heat, great optic transmissibility and a high resistance to corrosion.

CO2 laser markings on quartz glass are done through superficial fusion. The material’s fusion modifies the reticular structure of glass making light refract differently on the markings compared to the rest of the surface.

Boro-silicate glass

Boro-silicate glass, known commercially as Pyrex, is obtained by adding boron and other composites to the silica. The chemical reaction produces a glass that is highly resistant to thermal expansion. It is usually used for the production of flatware and oven trays.

Boro-silicate can undergo CO2 laser markings.

Contact us for more information on laser marking of glass.

The packaging and paper goods industry are the sectors which have most benefited from the introduction of the CO2 laser. This tool has triggered innovations in applications, production methods and in products.

Most of the laser’s benefits are due to the fact that it is a contactless tool. As opposed to traditional methods, lasers can follow a complex cutting path and allows for a much more flexible production. It can be used for complex applications and guarantees extreme precision at a high production speed.

Laser applications for security paper

Its precision and flexibility make laser technology perfectly suited for government issued paper and security paper.

Government issued paper and security paper have a number of inbuilt tricks to avoid being counterfeited and guarantee their originality. Security paper is usually employed by state or government agencies in the production of goods such as:

• official documents
• I.Ds
• bank documents
• checks
• banknotes
• shares
• certificates
• visas
• government stamps
• passports

In order to avoid tampering or counterfeiting there are many possible devices which include:

• watermarks
• security thread
• surface treatments
• holograms
• security windows

Each company has its own particular applications and patents. The producers of security paper constantly strive to make their product more innovative and tamper proof.

Laser technology makes some necessary applications to prevent counterfeiting possible. The fact that lasers can perform cuts at a controlled depth and follow complex processing paths make them ideal tools for this sector.

Kiss cutting, laser marking, perforation and laser etching are some of the possible applications. Let’s take a look at them, one by one.

Laser kiss cutting

This application is often used in the production of stickers. Kiss cutting consists of a very light cut on a piece of paper. Unlike normal laser cutting, the cut doesn’t go through the paper. It makes it possible to separate the sticker from the matrix, allowing the user to remove only the sticker. It is perfect for the production of government issued paper such as revenue stamps or postage stamps.

Laser scoring

Laser scoring is used to create folding lines on a piece of paper. The process is very similar to laser kiss cutting. Laser technology offers great control over all parameters. This makes it easy to decide the depth of the incision. The scoring, for instance, can be used to prevent the reuse of stickers or stamps. As soon as they are unstuck, they become irreversibly destroyed.

Laser drilling

Laser drilling is used to make little holes on a material. These perforations can have varying diameters and even reach microscopic levels. The drilling of indelible alphanumeric codes is one of its possible applications. The code becomes an intrinsic part of the document. Passports, for example, have serial codes inserted inside them.

Laser engraving

In laser engraving (a subset of laser marking applications), the beam is used to remove a superficial layer of material. This layer can have different depths and configurations. The engraved shapes can vary greatly from logos to alphanumeric codes, from symbols to images and all are indelible. Laser engraving can be performed on paper but also on other materials such as plastic. Plastic I.D cards are an example of this.

Polyester is the most common synthetic fibre used in the textile industry. Whether it be fashion, design, furniture making or decorations, there is no field in which polyester hasn’t found some application. Just open your closet and have a peak at the composition of your clothes. You will find that most are fully or in part made of polyester.

The success of polyester is due to both its properties and low cost. Objects made in polyester are easy to clean, more resistant and need less upkeep. Since polyester isn’t made of natural fibres, the cost of farming the original plants doesn’t factor in. The fact that polyester can easily be treated with laser is yet another advantage.

Polyester absorbs the CO2 laser wavelength very well which makes any type of process possible. Finishing processes can be optimised, therefore reducing production costs.

This article explores the main characteristics and advantages of laser cutting of polyester fabric.

Polyester and its properties

Many thermoplastic polymers are included under the name polyester. The one most frequently used to produce clothes is made from polyethylene terephthalate. The fibres production process starts from the fusion of polyester pellets. The next step is the extrusion of the material. In other words the melted polyester is passed through a hole to create a continuous filament. This filament is then rolled around a spool of the desired length. This method allows for filaments of any shape and diameter. They in turn constitute the fibre from which fabric is made.

Polyester fabric is long lasting, resistant, cheap, easy to clean, easy to dry and waterproof. These characteristics make it perfect for the production of all kinds of objects: clothing, footwear, interior design, car upholstery, camping equipment, etc… The impermeability of polyester can also be a disadvantage. It retains humidity and doesn’t have good breathability.

Laser applications on polyester

The characteristics of polyester fabric can be greatly improved by laser processing. As is the case for other thermoplastics, this synthetic fabric undergoes well both laser cuts and perforations.

Polyester, just like other synthetic plastics, absorbs the radiation of the laser beam very well. Out of all the thermoplastics, it’s the one that gives best results for both processing and lack of waste.

Laser cut on polyester fabric

Laser cutting of polyester offers many advantages over traditional cutting techniques. The cutting process works this way: the laser beam’s energy is concentrated on the fabric and heats the polyester fabric until it melts, creating a cut. The cut obtained is already sealed and therefore avoids the problem of fraying edges.

Other advantages are:

• No production of waste
• Extreme precision
• Very clean process

The right laser sources to use

In order to get the best results, the wavelengths should be between 9.3 and 10.6 micrometers. Both types of wavelengths are in the infrared region, which is the typical region of the carbon dioxide laser. The choice of the laser source power will depend on the speed of production one wants to obtain. The higher the power of the laser source, the faster the production. In El.En’s catalogue, two types of laser sources are right for the laser cutting of polyester:

Blade RF 177G

A 150 W RF CO2 laser source, specially conceived for applications on thermoplastics. It’s 150 W power is perfect for most applications that include plastic materials.

Blade RF self-refilling

A multipurpose RF CO2 laser source that uses the self-refilling technology, developed by El.En. This laser source is available in different power options, and can reach up to 1200 W.

The answer is a lot! The ability to make cuts with very close tolerances, down to a fraction of a millimeter, is one of the main advantages of laser cutting. In fact, laser is not subjected to the mechanical limits of traditional cutting tools.

The characteristics of the material impose intrinsic limitations to cutting mechanisms such as blades and hollow cutters. A blade, for example, must respect certain minimum dimensions to work properly. These dimensions mean that the blade cannot perform certain types of cuts such as very narrow ones.

Laser, on the other hand, does not have any of these drawbacks as it is composed of a polarized light beam focused on a very tiny spot. A CO₂ laser scanning head, such as AZSCAN S35, can focus a beam with a diameter ranging between 140 and 450 micrometers on a surface. Just to put things into perspective, a human hair is about 70 micrometers!

The fact that in laser technology there is no contact with the surface and the working dimensions are so small, makes it very easy to achieve extremely complex cutting geometries.

Also, laser cutting works well with all types of materials, from rigid ones, such as multilayer wood, to fragile ones, such as plastic film. They can all be processed easily and accurately, minimizing the risk of breakage and waste of material.

In addition to the previously mentioned advantages, laser also offers extreme controllability of parameters and a high speed of execution. All these elements combine to make CO₂ laser an incredibly powerful working tool. Flexibility, speed and accuracy open up infinite possibilities, especially for sectors such as packaging and fashion, which rely on creativity. Contact us if you wish to know more!

CO₂ laser is one of the technologies that boasts the largest variety of uses. The areas of application range from the medical sector to the restoration of monuments. Whether it is applied to skin resurfacing or eliminating writing from ancient walls, CO₂ laser is an incredibly efficient and cost effective tool.

But it is in the industrial sector that CO₂ laser truly shines. The high spectrum purity, high stability, energy efficiency, the possibility of multiple power options, ranging from a few to a thousands watts, are all characteristics that have determined its success in the processing of materials and made it reach high levels of quality.

The packaging industry

CO₂ laser is now an indispensable production tool for the packaging industry. The materials used (plastics, cardboard, wood and derivatives) and the characteristics of this sector’s typical processes (research of personalization, continuous innovation) are extremely compatible with the use of CO₂ laser, which widens exponentially its possible applications.

An example is the production of fresh produce bags using laser microperforation. The laser microperforation makes it possible to optimize the exchange of gas between the inside of the bag and the surrounding environment, which, in turn, makes it possible to extend the product’s shelf life.

One of the latest applications of CO₂ laser is the so-called natural branding. This recently developed application consists of marking the label directly on fresh produce’s surface. Information such as logos, tracking information and production batch can be directly visible on the products.

This information is traditionally printed on labels, which are then pasted onto the product. Laser labeling of fresh produce allows to avoid this step, thus eliminating the need for glue and other chemicals. This application is very effective and doesn’t damage the quality or durability of the product in any way.

Laser technology can also greatly enhance more traditional processes.

One example is the laser welding of plastic bags. This type of flexible packaging is increasingly used to save on space and create packaging adapted to different types of products. Laser welding can also be used for flexible packaging. This process uses laser energy to heat the material and thus seal the bag.

The second application is laser engraving of flexible bags. This application uses the extreme controllability of laser technology to create depth-controlled incisions on the plastic material. With this technique, it is possible to create easy-to-open packaging or innovative packaging for ready-to-use products.

The fashion and interior decoration industry

Carbon dioxide laser is used in the field of fashion and interior design. CO₂ laser can become a powerful creative tool in the hands of architects and designers. It is also an environmentally sustainable tool which significantly reduces the ecological impact of the textile industry.

Laser marking, microperforation and cutting are the main operations used in this field.

Laser marking is mainly used to engrave decorative patterns on fabrics and leather. The great advantages of CO₂ laser are high manufacturing speeds, precision, elevated repeatability of impression and the possibility to engrave any type of geometric pattern or design.

Laser marking also finds innovative applications in the field of textiles. One example is the use of laser marking of denim fabric. It is now possible to laser wash jeans. This method significantly reduces the consumption of chemicals and water.

The laser decoration of ceramic tiles is another CO₂ laser applications for the interior design world.

Again, the main advantage of this laser is the almost infinite range of motifs that can be transferred onto the tile’s surface (from simple geometric motifs to real black and white photographs).

The food industry

The food industry recently discovered how useful the carbon dioxide laser can be. In these applications, laser is used to carry out work directly on the product’s surface, thus replacing the use of mechanical devices. Some examples of these CO₂ applications are fruit and vegetable laser peeling, laser marking of codes on eggshells, laser engraving of cheeses and cured meats.

Digital converting

Laser technology fits perfectly into a digital manufacturing process. Indeed, the CO₂ laser’s characteristics are best appreciated when it is inserted in highly automated processes.

An example of a successful application is paper processing. Thanks to laser technology, it is possible to create integrated systems capable of printing, punching and cutting paper into a desired size. All kinds of details and customizations can also be added with laser which would be impossible to do when relying on the mechanical methods traditionally used in this sector.

Laser is also ideal for the production of security paper. Codes, perforations, cuts and other identification marks can be added quickly and easily.

Tool industry

The production of tools and tooling in general can greatly benefit from the use of laser. In the case of laser surface hardening treatments, the metal surface is exposed to the effects of the laser beam, causing an internal transformation of its molecular structure which increases the wear resistance of the tool.

Panel industry

Extreme controllability is one of the strengths of laser processing. For the signage industry this aspect translates into a huge advantage. The CO₂ laser makes it possible to engrave writings, logos or other information with extreme precision and high definition on the most commonly used materials for panels and signs such as plexiglass, steel or aluminum. Laser technology also makes customizations easy.

Display industry

Acrylic laser cutting is one of the areas in which CO₂ laser is unbeatable. The paneling industry has benefited greatly from the use of CO₂ laser. Laser is in fact indispensable in the manufacture of LGP Backlight panels.

These are PMMA panels which are perforated at regular intervals using laser. The panel, thus prepared, is then illuminated by LEDs which, suitably positioned, create a uniformly illuminated surface. The main advantage of these displays is that it is possible to create large backlit panels with very low energy consumption.

Laser technology is indispensable to this type of manufacturing because holes can be drilled with a precision and regularity that would be extremely difficult and expensive to obtain using traditional production methods.

Automotive industry

Some of the most common CO₂ applications in the automotive sector are decorations of plastics, surface hardening of metals, microperforation of leather for interiors, decoration of upholstery, welding, engraving of codes for the identification and traceability of parts, etc.

In fact, this industrial sector was one of the first to introduce the use of laser in its manufacturing processes. It is therefore no surprise that the CO₂ laser is so widely used.

One laser, multiple uses

Ultimately, CO₂ laser has an almost infinite range of uses. Its wavelength makes it suitable for the processing of most materials. Contact us for more information: there might a laser solution to your problem.

Thermoplastics are polymeric materials with incredible properties. Their name derives from their main property: becoming viscous when heated and solidifying once cooled.

These characteristics makes it possible to laminate and easily shape these materials. Industrial applications are endless: from the packaging to medical devices sector, without forgetting the electronics, automotive and food industries. There is no sector in which thermoplastic doesn’t have a key role.

On this blog we have already seen how thermoplastics work well with laser technology. Microperforations, cutting, kiss-cutting are but a few examples of how well thermoplastics absorb the CO2 laser wavelength and offer great flexibility and high quality results.

Now, thermoplastic polymers can also be used in a foamy state. Polymeric foams, or expanded polymer, are obtained by treating the polymer chemically or physically until the right shape is obtained. Expanded polystyrene, expanded polyurethane and expanded polyethylene all belong to this category of materials.

Expanded polyethylene (aka polyethylene foam) is one of the most popular foams used in the industrial sector, due to its lightness, insulating properties and resistance. This foam is ideal for laser cutting.

In order to cut polyethylene foam, a CO2 laser precisely and cleanly outlines the wanted shape in the polymer foam. This process is easily controlled digitally. The advantage of using laser technology is that the pieces are cut perfectly, down to the last millimeter and in a well defined shape. It is therefore ideal for highly detailed work.

An example of what co2 laser can do is tool shadowing. Basically it means cutting a layer of foam with cut outs of different sizes for each tool in your tool box. The tool will be perfectly kept still and safe inside the toolbox.

Making this application using only mechanically tools is very difficult if not impossible, because the expanded polyethylene sheet would have to be pinned down in order to cut out the shapes without ruining the material. This method works only if the shapes have straight lines. As soon as the lines are curvier or more detailed, it becomes difficult to trace the objects outline perfectly.

Laser technology makes it easy to cut polyethylene foam in the right size and shape. All you need to do is create a CAD file with the shapes to cut out. The file is then transferred to the software making it possible for even the most complicated of shapes to be created.

The packaging sector has numerous applications for CO2 laser. There is nothing surprising there since the materials best suited for packaging are also the ones, due to both composition and shape, that work best with CO2 laser technology.

In previous articles, we have already seen some of the CO2 laser applications on materials such as thermoplastic film, wood and some of its by-products like MDF and paper and cardboard for innovative forms of packaging. The distinctive wavelength of CO2 laser makes cutting, perforation, incision and marking particularly efficient and cost effective.

CO2 laser is an efficient and versatile tool for the laser welding of thermoplastics, a popular technique used in the packaging sector. This process takes advantage of the fact that thermoplastics are easy to work with once they’ve been through a thermic treatment. In layman’s terms, the welding process consists of heating the area where the two thermoplastic pieces join with the laser beam until fusion point is reached.

This process can be applied to different types of plastics, either laminated or molded, opaque or transparent. There are many advantages to laser welding:

• it’s a very fast process
• like all laser processes, it’s extremely precise and easy to control
• it doesn’t leave residue or waste
• it doesn’t expose pieces to thermal or mechanical stress because the heated area is localised and the process isn’t mechanical
• it’s highly automatable and easy to integrate with other systems, whether they be digital or analog

These characteristics have made it a tool of choice in sectors where precision, cleanliness and the absence of thermal or mechanical stress are determining factors. The production of biomedical devices or electronic devices, the production of parts and components for the automotive industry, the production of airtight packaging for the pharmaceutical and food industry are all examples of the applications of laser welding.

Laser welding for plastic film

In the world of packaging, laser welding is most used on laminated thermoplastics. The laser of choice for this technique is the CO2 laser.

Direct welding is the type of welding that works best with thin materials. As opposed to transmission laser welding used mainly for three-dimensional and moulded pieces, direct welding operates directly on the material. This process allows for a higher speed of productionand therefore increases productivity while lowering production costs.

The materials most used in the packaging industry are:

• nylon
• polyethylene
• polypropylene
• acrylic (PMMA)

The interaction between the laser beam and the material cannot be predetermined. Many factors come into play: the type of polymer, the existence of added additives to the formula, the laser beam’s speed of movement on the surface and the laser beam’s intensity itself.

But as a general rule, the laser’s effect is stronger on the material’s surface and decreases the deeper it gets. Adding carbon to thermoplastics can highly increase the material’s capacity for energy absorption, thus making the laser much more efficient.

Laser welding is perfect for the production of original packaging that brings added value to the product because it can work in a very localised way on complex shapes.

Equipment for laser welding of plastic film

A laser system for laser welding needs different components. The fundamental ones are a laser source, a scanning head and a software system to program and control the process.

Apart from the afore-mentioned items, a laser welding system should also include devices for product management, loading and unloading, and powering the laser source.

In conclusion, laser welding applications are numerous since laser technology is so versatile. It can be adapted to completely digital processes or be integrated with analog production lines. This technology greatly lowers production costs and not only increases productivity but also the quality of the product.

CO2 lasers are one of the most widely employed technologies in manufacturing. The technology is so flexible and powerful that it is installed on a large number of industrial machines, used in a wide array of sectors. CO2 laser sources are well renowned for their resiliency: a machine based on this technology insures thousands of hours of high quality work.

This type of laser still needs periodical maintenance work. Its weakness is a slow but inevitable loss of power.

Gas leaks, CO2 lasers’ weakness

Excessive gas leakage has consequences on the laser’s output. Its power will either decrease over time or be reduced drastically all of a sudden during operation. This phenomenon produces a reduction in the quality of operation: the laser beam becomes unstable and precision work is compromised. When that happens, laser maintenance is necessary.

Maintaining CO2 lasers

Maintenance can be done by the producer or by a company specialised in this sort of operations. Generally, maintenance work includes disassembling the machine and refilling the gas tube. Many specialised companies offer this type of service, which often also includes the cleaning and realignment of the optics and other components of the laser source.

These operations, even when carried out by professionals, do expose the laser source to potential infiltrations of dust and other microscopic foreign bodies. This sort of infiltrations could compromise the laser beam quality and, as a result, the good working conditions of the machine. Transporting the machine to the maintenance service facilities can also expose it to accidental damage.

It is important to bear in mind that every maintenance will cause a standstill of production that can last from a few days up to a few weeks.

The advantages of El.En’s Self-Refilling technology: Never Ending Power

As a solution to the drawbacks of maintenance, El.En.’s research and development department has developed an innovative Self-Refilling technology. Thanks to Self-Refilling, gas-refilling operations can be carried out directly in-company.

The Self-Refilling system is based on disposable CO2 gas canisters. Every laser source has an in-built lid-protected slot for gas canisters. When it is time to refill the laser source, one needs to simply open the lid, take the empty canister out and put a new canister in. This way the laser source will maintain its max power and its operational standards will be preserved. Servicing operations can be carried out manually and without the laser source producer’s assistance.

The ability to independently refill a CO2 laser source brings about several advantages. Here are some:

• interruptions to production are reduced to a few minutes
• crucial parts of laser sources, such as the optics, stay sealed
• chances of infiltration of dust and foreign bodies are greatly reduced
• chances of damages from transportation are reduced

There are huge savings on resources and the laser source is always at max power and efficiency.

The Blade RF series of Self-Refilling CO2 laser sources are equipped with this innovative technology. These sources all have a compact design, come in multiple power options and can operate on a large variety of materials. Explore our range of products and discover the vast array of available applications.