The synthetic leather market has seen exponential growth in recent years. Natural leather is becoming an increasingly scarce commodity, both for economic and environmental reasons. On the one hand, the need for finished products at ever lower prices limits the use of expensive raw materials, and on the other, animal and environmental issues are driving companies to choose eco-friendly solutions.

Synthetic leather is very similar to natural leather from both a technological and sensory point of view. Unlike natural leather, it is not a breathable material. It also needs a base layer, often made of cotton or other natural fibres.

The advantages of synthetic leather over hide are many:

• production costs are very low
• the production batches are very uniform
• textures and effects that do not exist in nature can be produced
• it is easier to cut and sew

Far from being a less noble alternative to the original material, synthetic leather is a practical and modern material. It can be successfully used everywhere traditional leather was, with the same aesthetic and technical results.

The composition of artificial leather

Synthetic leather is made up of two layers, an upper one that imitates leather and a lower one acting as a base.

The upper layer is composed of a synthetic polymer. The most used materials are PVC (Polyvinyl chloride) and Polyurethane (PU). The two materials differ slightly. Most synthetic leather is made of PVC due to its low cost and greater resistance. Polyurethane, a costlier material, is less frequently used even though it feels more like real leather to the touch.

The artificial leather base is in fabric which can be made from synthetic fibres, natural ones (usually cotton) or even natural-synthetic blends.

The role of the fabric base is very important. The mechanical properties of synthetic leather rely on the strength of its base. The lifespan of synthetic leather is in direct correlation to the one of the fabric base.

Can you laser engrave faux leather?

The answer is yes, you can. Due to its thermoplastic polymer composition, synthetic leather lends itself very well to laser processing, particularly with CO₂ lasers. The interactions between materials such as PVC and Polyurethane and the laser beam achieve high energy efficiency, ensuring optimal results.

Laser marking and engraving

The marking and engraving processes are very similar. In both cases, the laser beam acts on the surface layers. The laser energy activates alterations which, depending on the intensity, can be more or less deep or radical.

In marking processes, the applied energy density is very low. The material’s transformations stay at a superficial level and are more aesthetic in nature.

In laser engraving, the applied energy density is higher and reaches deeper layers of the material. It therefore undergoes substantial chemical transformations. The marking is more visible and contrasted. The end result can have a tactile finish and even a natural texture.

Laser parameters

The system must be set according to certain parameters to achieve the desired laser marking or engraving effects. There is no universal rule one can follow to set the system. The correct parameters depend on factors such as:

• the type of material used: polyvinyl chloride and polyurethane absorb energy differently. So the settings must be regulated differently.
• the colour of the leather: light coloured leather is more reflective than a darker one. Dark leather therefore absorbs the laser beam better, resulting in greater energy efficiency and faster processing.

A correct laser setting will aim to achieve the correct energy density in order to obtain a clearly visible mark without damaging the material.

Laser Engraving Systems

Leather marking/engraving is one of the applications of galvo scanning. This category includes all processes in which the laser source is used in combination with a scanning head.

The scanning head distributes the laser beam produced by the source on the material’s surface.

Laser sources and scanning heads are available in different models depending on production needs. In order to make the right choice, it is necessary to know your particular manufacturing characteristics. Send us information about your production plant and requirements and we will be happy to design a tailor made leather laser marking/engraving system to suit your needs.

The clothing industry is the second biggest polluting industry, being just behind the petrol industry. To give you an idea of the massive impact the fashion industry has on the environment, consider this: it is estimated that 10% of world’s greenhouse gas emissions are generated by the textile industry.

The textile industry is all but harmless to the environment since its production processes consume a lot of resources such as water, energy and chemicals for the finishing process. This has led the industry to research more sustainable and eco friendly processes.

One of the most polluting phases of the production processes in the clothing industry is the finishing process, e.g. fabric decoration. Research shows that laser technology currently is the most eco friendly and sustainable application that can be used to decorate clothing and fabric. Not only did the laser technology stand out as a viable and efficient technology, but it also allowed designers to innovate products and designs.

To be honest, the use of laser technologies in the clothing industry is not entirely new, but dates back to the early 60’s. From that moment on, researchers noticed the diverse advantages of this technology, such as precision and lack of wastes. After years of research, experimentation and applications, the CO2 laser has proven to be the most suitable technology for the fashion industry. The use of the CO2 laser is beneficial in terms of design as well as in terms of the company’s resources. All desired designs can be achieved, with millimetric precision, by applying the very vast and efficient laser marking processes on the fabric. The energy efficiency and the running speed of a CO2 laser source are incomparably superior to any other traditional production technique, resulting in a significant decrease of energetic resources. Furthermore, the technology solely modifies the surface of the material – this means that there is no need for water consumption or polluting chemicals.

Laser engraving for fashion design does not know limits in terms of versatility. Nearly all materials normally employed by the textile and clothing industry can easily be worked by the CO2 laser. The technology can engrave or mark either natural or synthetic fabrics. Recent studies have also revealed that this technology is highly suitably for the discoloration of clothing, in particularly jeans cotton.

The CO2 laser is especially suitable for the clothing industry due to its particular wavelength, which is well absorbed by non-metals and organic materials as they are bad conductors of heat and electricity. This allows you to achieve optimal results while consuming the least possible amount of energy resources. Inks, chemicals, and solvents are eliminated and there is thus no longer a need for large amounts of water: the eco-sustainability of the CO2 laser is thus evident.

This is also demonstrated by a recent study¹ that analyzed the outcomes of laser decoration and innovative designs on wool and polyester fabrics versus decoration achieved by means of chemicals. The research paid particular attention to the weight, thickness, perspiration, thermal conductivity, and strength of the fabric after they had been engraved or marked. Both production methods have been tested with simple as well as complex patterns. The results have shown that the laser technology method performed better in all of the above named aspects, in comparison with traditional methods.

Besides that, the laser technology has also shown better results in terms of speed, precision, and resource consumption.

In conclusion, laser engraving for the clothing and textile industry is a more efficient, sustainable, and eco-friendly process than traditional methods of decoration.

¹Application of Laser Engraving for Sustainable Fashion Design, G.X. Yuan, S.X. Jiang, E. Newton and W.M. Au, Research Journal of Textile and Apparel 2013 17:2, 21-27.

Laser die cutting of labels is a digital converting process. In this application, the laser die cutter replaces mechanical dies in the execution of processes such as the cutting or trimming of label templates.

The use of laser technology is particularly advantageous. On the one hand, it overcomes the typical disadvantages of mechanical die cuts. On the other hand, it allows the same processes to be performed with a flexibility and precision impossible to achieve with diecuts.

In this respect, the laser die cutting process clearly shows the advantages of using lasers for labeling and packaging applications.

How the label production process works

The production of self-adhesive labels is one of the most traditional papermaking operations.

Typically, the label production process takes place in 3 steps:

• printing of the label on the master sheet
• engraving of the label template
• cutting of the label template

The die cutter is used for the operations of engraving the label and cutting it out from the master sheet to isolate the label from the sheet itself.

This processing technique has several disadvantages:

• in order to obtain new shapes to cut, manufacturers must create a new die cutter
• the mechanical properties of the tool do not allow complex shapes to be cut
• the cutting tool wears out quickly and needs maintenance to work efficiently

Given those features, a mechanical production system is only efficient if it can guarantee high production volumes. However, the market today rewards companies that are able to offer innovative, customised production processes that can support numerous orders with small production volumes. And from this point of view, a laser cutting machine is the optimal production tool.

Laser processing of labels

Laser die-cutting is based on an ablation process. The operation is carried out by a laser machine. The beam laser power, focused on the material, removes a portion of material through a chemical process called sublimation. By means of devices such as galvo laser head, it is possible to move the laser beam along a determined path. Digital control also makes it possible to precisely calibrate the instrument according to the desired type of processing. The operation is carried out at high speed.

There are two possible operations: laser kiss-cutting and laser cutting. Both are laser cutting processes, but differ in how deep they cut the material.

Laser kiss-cutting and laser cutting

Laser kiss-cutting consists of cutting the surface layer of a multilayer material. Adhesive labels are printed on master sheets. These sheets typically consist of two layers: a top layer on which the graphics are printed and a backing layer, onto which the adhesive is glued. In laser kiss-cutting, the laser engraves only the surface, freeing the adhesive template from the backing matrix.

In laser cutting, the beam passes through all the layers of material, freeing the adhesive from the matrix and reducing it to a unit.

The advantages of laser label die cutting

Laser finishing offer numerous advantages:

• the cutting path can be modified by simply loading a new file into the system
• the absence of mechanical contact allows particularly complex cutting paths to be followed
• laser cutters does not wear out and requires minimal maintenance

For a company using a digital laser die, it becomes possible to manage production in an innovative way. It can now make prototypes for the customer, start small volume production runs and accept numerous orders that wouldn’t be sustainable with traditional production methods. It is a true paradigm shift in the way we conceive production.

There is yet another advantage. In the digital converting industry, and particularly in paper converting, CO2 lasers are almost exclusively used. These laser systems are known to interact very efficiently with paper materials. This characteristic, coupled with the reduced production of processing waste, makes the laser an eco-friendly production tool.

Contact us

El.En. has developed numerous digital converting applications over the years. Contact us to find the application that best suits your needs.

Microperforation is a laser process that consists in creating micro holes on a sheet of raw material. Microperforation makes it possible to precisely choose the size, depth and quantity of holes per square centimeter. The flexibility of this technique makes it easy for the operator to change the processing characteristics according to the intended final use of the piece.

There are many examples of this processing technique from various sectors:

• the paper industry where microperforation is used to create security paper, i.e. paper products with special features to make counterfeiting very difficult
• the industry of fabrics and leathers, microperforation can be used to add decorative elements but also to improve the breathability of materials
• a similar application is in the automotive sector, where for example, microperforation is used in the finishing of leather for the internal lining of cars
• the packaging sector, microperforation is widely used. It is used to microperforate the plastic film used for packaging in modified atmosphere because the size and density of the holes can be adjusted with great precision
• Finally, a last example comes from the field of soundproofing. Sound absorbing tiles that perfectly muffle a specific type of frequency, are made with laser microperforation

The advantages of laser microperforation

Microperforation has several advantages over traditional applications. Here are two:

• Precision. Laser can perfectly calibrate the density, number, size and internal shape of the holes. Microperforation therefore allows you to create processes perfectly suited to the intended use of the product
• Flexibility. Different materials can be processed using the same laser source. CO2 laser sources are unbeatable for their flexibility of use

What materials can be processed with laser microperforation?

CO2 laser microperforation works best on flexible natural and synthetic materials. Some of them include:

• thermoplastic polymers, materials such as PMMA, polyethylene, PP and PET are among those most used in the packaging sector and suitable for this type of processing
• leather and hides
• fabrics made from natural and synthetic fiber
• paper and cardboard

Which laser source to choose to execute laser microperforation?

There are many factors to take into consideration when choosing the right laser source for microperforation.

One must consider the material being processed as well as the desired production outcome and process speed. Based on these elements, it is possible to establish the best wavelength and the power to use to get the job done.

Although finding the laser solution that best suits your needs may seem impossible, don’t worry, our experts have extensive experience on the field and will be able to help you find the laser system that’s right for you. Contact us for more information!

Let’s continue our journey of discovery of the different CO2 laser applications for the packaging industry. In the past articles, we’ve already described how laser micro-perforation can drill accurate holes on plastic film to create packages suitable to preserve fresh food. Laser micro-perforation applications, unlike traditional mechanical micro perforation applications, offer speed, flexibility, and extreme accuracy.

In order to improve the shelf life of products, it is often necessary to continuously control gas exchanges between the interior and the exterior of a plastic bag. Laser micro-perforation allows us to tightly control these gas transmissions, allowing us to easily package fresh products as well as preserve their quality.

It is no coincidence that the CO2 laser has seen a broad application in this field. The packaging industry knows very strict production rules and specifications. Packaging must not only guarantee the quality of the product, but must also meet requirements in terms of mechanical strength, packaging hygiene, and food safety. Besides that, all requirements also have to be reconciled with an aesthetic appearance. Poor packaging could reduce the perceived quality of the product, and is thus a crucial factor in influencing consumer buying behavior.

In this article we’re going to describe another application of the CO2 laser: we will talk about sealing plastic food bags.

Conventional methods to seal plastic food bags

Why is the CO2 laser an innovative process for the sealing of food bags? To get an answer to this question we have to briefly discuss the traditional methods used to seal plastic food bags.

Traditionally the sealing of plastic food bags is a welding process achieved through the application of heat and pressure. In this process, two sheets of plastic film are joined and welded together. This process is mostly mechanical, meaning that parts of the machine have to be changed every time a different packaging process is executed, in order to meet the packaging needs of diverse products. Traditional machines are heavy, due to their working parts that need to be fastened securely.

A production line of this kind is not flexible, while food manufacturers may need to apply different packaging techniques within the same production cycle. This would mean that the manufacturers have to the change machine parts or perform other maintenance operations, which results in lower productivity.

Laser hermetic sealing plastic food bags

The process of laser sealing of plastic bags is part of the hermetic welding process of thermoplastics. The most commonly used bags in the packaging industry are transparent and made of polypropylene or polyethylene.

These materials absorb the 10.6 μ wavelength of the CO2 laser very well. The laser beam reaches the surface of the material to be welded thanks to a scanning head. Subsequently, the laser heats up the surface so as to reach the melting temperature of the material, allowing it to weld the two plastic films together.

The entire process is incredibly fast: the speed achieved with this welding method to hermetically seal plastic bags allow to seal dozens of pieces per minute.

What are the advantages of hermetic laser sealing?

The advantages of using a laser sealing system to hermetically seal plastic food bags are endless:

• You can change the shape and size of the packaging material to be sealed without the need for long breaks in the production flow. It is not necessary to create custom-made parts since the laser can be applied to any type of container and to any type of machining even within the same production cycle.
• The sealing can even be carried out on very thin plastic films without risking any damage to the material. This allows extremely accurate machining operations and reduces the amount of material used, and thus reduces industrial waste.
• The CO2 laser is compact in size and light in weight since mechanical parts or other bulky mechanisms are not required. The laser system thus fits well into production facilities with confined spaces.
• Like any other laser process, the welding of plastic bags is a non-contact process. This means, among other things, that it is aseptic, and thus perfect for the packaging of food products.

Required components for a laser system setup

You may ask yourself right now which components are required for a laser system set-up. It is difficult to define in detail the diverse components or elements that will be part of the system. Each customer has its own needs in terms of power, production speed, material to be treated, etc. However, it is possible to define the following three basic elements of a similar system.

CO2 Laser source

The CO2 Laser source generates the laser beam that will work your materials. El.En. CO2 laser sources are available in different output powers, ranging from 150W to 1200W.

Laser scanning head

The laser scanning head is a device that “moves” the laser beam while keeping it perfectly focused on the point that needs to be worked. El.En.’s scanning head executes this process at very high-speed thanks to the beryllium mirrors mounted on galvanometric motors.

Control Software

The advantage of laser processing is that the entire process is controlled digitally. Through the software, you can control all relevant machining parameters and perform on-the-fly changes without interrupting the process workflow.

Abrasives, part of a family of materials characterised by their great hardness, are used for processes such as polishing or the sanding of surfaces. They are available in a wide variety of shapes and types and lend themselves to a multitude of processes.

These materials can be moulded into a large number of shapes: discs, brushes, wheels, cutters, grinding wheels. However, traditional abrasive processing methods have limitations that can be overcome with laser processing.

In this article we will look at the 6 advantages of using laser technology in the manufacturing process of abrasive products.

1. Laser is a non-contact process

The main problem in the manufacturing of abrasives is that the abrasive action is also exerted on the tool itself. Let us take flexible abrasives as an example. In this category of abrasives, the abrasive substance is sprinkled on a backing, which is normally made of paper or a polymer material. In order to obtain the desired shapes, such as a rotating disc or wheel, tools such as dies are used, i.e. a mechanical method that uses contact between parts to separate an element from the die into the desired shape.

Operations such as die cutting of abrasive materials, however, have a drawback. The abrasive action is also exerted on the cutting tools. Blades, dies and cutters quickly get worn out and must be replaced frequently to maintain high machining quality. This increases machining costs, which consequently increases the cost of the final product.

Laser cutting of abrasive materials overcomes this disadvantage. It is characterised by a total absence of contact. The laser beam interacts remotely with the surface of the material in a non-mechanical process that avoids the problem of continuous wear of the machining tools.

2. Laser is a versatile tool

A major disadvantage of traditional machining methods is also their lack of flexibility. For example, a die made to create a specific shape can only be used to create that specific shape. To make differently shaped parts, it is necessary to create new diecuts, provided that the investment required to create them is justified by a profitable return.

Similarly, only one machining operation can be performed with traditional machining tools. A die-cutting tool can only perform one machining operation. A cutting tool can only perform cutting. To perform different machining operations, one must change the machining tool. If a manufacturer wanted to apply information to an abrasive disc such as grit size or a serial number, he would have to insert the part into a dedicated machine, such as a printing machine.

Laser systems, on the other hand, allow several machining operations to be performed in a single session. With the same system, flexible discs can be cut from a die, cuts and perforations can be made and surface information on a material can be added through laser marking. In addition, the use of lasers allows the shape or size of the piece being manufactured to be changed in real time, without any additional aids. It is precisely its high flexibility that makes the laser the trump card for this type of application.

Laser offers a true change in the very way production is understood. It gives manufacturers the possibility of enormously expanding their commercial offerings. It becomes possible to create prototypes, just-in-time production, or series of small parts for high-value customers.

3. Laser is a precise tool

Abrasives are used in many different industries. Each of them requires specific processes, and, therefore, abrasive tools that are shaped differently. This means that there are more or less specialised tools: from simple sandpaper, sold in rolls and used by carpenters and craftsmen, to customised rotating discs for high-precision machining.

However, mechanical machining tools have a tolerance limit beyond which they cannot go. The size of the machining tools, their design, and the need to avoid unwanted contact limit the complexity of the machining that can be performed.

Laser, on the other hand, allows very tight tolerances. Since there is no contact between the parts, the tool can follow intricate cutting paths, create microscopic perforations and special shapes, make surface cuts and other machining operations that would be impossible with mechanical cutting tools.

4. Laser reduces machining waste

With traditional machining tools, processing is performed by the mechanical removal of material. The process tends to produce machining waste, dust and other residues that must be managed in some way, with a variable economic and environmental cost.

Laser machining processes, on the other hand, tend not to produce waste. Material removal occurs through sublimation. The very high energy density produced by the laser on the surface allows the temperature of the material to rise, instantly vaporising it as a result of a transformation of the material state.

5. Laser respects materials

Mechanical machining processes present a risk of damage to products due to accidental contact or excessive mechanical contact. Any deformation lowers the quality of the final product.

In laser processing, there is no risk of damage from mechanical contact. Laser processing respects all materials, even the most delicate ones. They guarantee a higher quality of the finished part and are therefore ideal for the sectors in which the degree of error must be kept down to a minimum.

6. Laser is an environmentally friendly process

Laser processing offers high energy efficiency. All things being equal, laser performs the processing with much lower energy expenditure than mechanical processing. This, combined with the absence of waste, makes the laser one of the most environmentally friendly processing tools available to manufacturers.

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Laser is a cost-effective tool for the manufacturing of abrasive materials. Because the possible applications are numerous, seeking the advice of an expert can help you find the most suitable processing system for your application. El.En. CO2 laser systems are ideal for the manufacturing of abrasive materials. Contact us for more information.

Plastic processing was one of the sectors in which the introduction of the CO₂ laser was immediately appreciated. Laser has made it possible to carry out faster, more precise and less wasteful processes.

Flexibility has been the watchword that made new methods possible andopened up new areas of application for plastic processing.

The word “plastic” is quite inaccurate: it covers a large number of materials which have very different behaviors, mechanical characteristics, workability and possible applications.

Cutting, drilling and marking are the main processes that can be carried out with CO₂ laser. Plastic objects are cut by gradually removing the material until the laser beam penetrates through its entire thickness.

Some plastics lend themselves more to cutting than others. The best results with laser are obtained with acrylic (PMMA) and polypropylene (PP). On these plastics, the cut comes out with smooth, shiny edges and without any scorch marks.

CO₂ laser marking for plastic is based on the same principle as laser cuts; though in this case, the beam only removes a surface layer, leaving an indelible mark.

In theory, laser can mark any type of logo, code or figure on plastic, but in reality, the possible applications depend on the material used. Some materials respond better to cutting operations, while others are more suitable for marking.

But what does this great variability of behavior between one plastic and another depend on? The difference lies in the different disposition of the monomers, the repetitive molecular units within the polymer. Variations in temperature have an effect on the material properties and behaviour.

In fact, all plastics are processed with the use of heat. Depending on how they respond to it, plastics fall into two categories: thermosets and thermoplastics.

Examples of thermosetting polymers are:

• polyimide
• polyurethane
• bakelite

The main thermoplastic polymers are:

• polyethylene
• polystyrene
• polypropylene
• polyacrylic
• polyamide
• nylon
• ABS

Thermoplastic polymers, up to a certain threshold (called glass transition temperature), behave like a crystalline solid. Beyond this temperature they first transition to a rubbery state and then finally melt. These polymers are made up of linear chains, which explains why they can be melted and easily molded at certain temperatures.

Thermosetting polymers on the other hand, stiffen as the temperature increases until they reach melting point, beyond which a change of state occurs. Cross-linking within the macromolecule, makes them less susceptible to temperature differences.

Because of these substantial differences, not all plastics respond well to laser. In general, thermoplastics lend themselves better to laser processing, but even thermosets can, to some extent, be subjected to laser processing.

In the following tables we have summarized the result of the interaction between the various polymers and the laser.

As you can see, the results vary widely. A case by case analysis is recommended to understand which application works best. Plus, more plastics can undergo laser cutting: teflon (PTFE) is on of those.

How to choose the right laser system for plastic

The introduction of laser in plastic processing has paved the way for new applications. Laser processing of plastic is very convenient. Most commonly used polymers are perfectly compatible with the CO₂ laser.

But choosing the most suitable laser system is not easy. The variables to take into consideration are many: the type of application, the type of material, and the production needs.

El. En. has produced laser systems for plastic processing for over 35 years. If you have an application in mind and aren’t sure how to make it, contact us. We will be more than happy to help you.

Wood, paper, cardboard, plastic, PMMA. And also rubber, leather, metals, and ceramics: CO2 lasers can cut a great number of materials. For this reason, CO2 lasers have become the most widely diffused laser technology for laser material processing.

However, despite the wide use of the CO2 laser we receive a lot of questions on possible appications that can all be summed up by what materials can be cut by CO2 laser? In this article we answer to this question with a simple list of materials that can be easily cut with CO2 lasers (the links take to articles that examine each topic in depth): 

• Wood based materials
• Paper based materials
• Acrylic (PMMA) and other plastic polymers
• Leather and faux leather
• Natural and synthetic fabric
• Biologic materialAll industrial sectors that need to process these materials can thus use the laser CO2 for a faster, smoother, and more precise cutting process.

Fields of application

To go into the details, the following list displays the main applications of CO2 laser cutting, ordered by industry:

• Papermaking industry
• Cutting cardboard boxes
• Cutting paper and cardboard
• Stencil cut
• Decorations

• Woodworking industry
• The cutting of any kind, and thickness, of wood, especially Plywood and MDF
• Inlay fine wood
• Engravings of any kind

• Engravings and inlays
• Laser engraving and cutting methacrylate
• Laser engraving and cutting leather goods
• Laser engraving name and number plates
• Laser engraving and cutting textiles
• Laser engraving electronic components
• Laser engraving anodized aluminum and varnished metals. N.B.: the CO2 laser usually doesn’t cut metal but can label or mark them indelibly.
• Engraving of glass, marble, and stones
• Inlays on ivory

• Creation and Customization
• Laser cutting hollow punches
• Laser cutting for architectural models
• Laser cutting plastic, cardboard, or wooden displays.
• Contour and cut labels
• Personalizing gadgets
• Personalizing buttons
• Material machining for model making

The list above is just a short list of the many different materials that can be processed by the CO2 lasers: there are lots of other materials that can be cut with the CO2 laser. Research on the applications of the CO2 laser is still an ongoing process, of which experimentation plays an important role: only experimentation provides us with certainty about the possible applications. For this reason we invite you to contact us whereby the material you want to work is not presented in the above list. Together we will find you the solution that fits your needs!

Laser cutting of wood-based products is one of the most important applications of CO2 lasers. Today, laser is a powerful, flexible and reliable tool: it made it possible to overcome the limits imposed by the traditional methods of machining wood based materials.

The advantages of laser production are many. Here’s a few:

• it tremendously speeded up operations such as cutting, drilling or marking on various materials
• it allowed to extend the use of materials such as engineered wood products for the production of parts and components
• it allowed operations that couldn’t be achieved with traditional, mechanical, applications, due to the limits of either the material and the machines

It’s no coincidence that one of the first commercial applications of CO2 lasers was the cutting of plywood die boards for the packaging industry. This sector in particular has really benefitted from the advent of laser-based production methods. The reason is that CO2 lasers are perfect for machining wood, paper, cardboard and similar products, largely used by the packaging industry. CO2 laser cutting opened up a new range of possibilities for this industry.

But how does the CO2 laser cutting process work?

CO2 laser cutting, a precision technology

The laser cutting process in itself does not involve any mechanical force. It relies upon the physical and chemical processes that take place when a focused laser beam hits the surface of a material.

A high intensity beam of light is generated by a laser source, like one of our BLADE RF Self Refilling family. This laser beam is then reflected by a system of mirrors, until it passes through a lens which focuses the beam down to a small spot onto the surface.

This means that, in a single spot a fraction of a millimeter wide, is concentrated all the energy generated by the laser. The spot thus reachers a great energy density which causes the immediate sublimation of the material surface touched by the laser. In this way the  desired cut is produced.

Despite the highest energies involved in this operation, laser cutting of wood is a very safe process. The entire operation is controlled by a computer, resulting in great accuracy. The cutting kerf is very narrow and precise and no damage is possible, provided that the laser is properly set.

The cuts obtained in such manner have some unquestionable qualities:

precision: the CO2 laser provides accurate cuts. The energy is focused precisely on the spot indicated by a software. Since the dimensions of this point are very small, working tolerances are very tight, allowing very complex profiling paths

smooth edges: the edges obtained from CO2 laser cutting don’t need further finish because they all have a polished appearance

Reduced costs: the laser cutting of wood results in the absence of any sawdust, shavings or other leftovers. This, combined with the lack of blades or other mechanical tools, create a very quiet working environment

Laser cutting of wood can be achieved on different types of woods. The results can vary a lot, depending on parameters such as the type of wood, its density and resin content and, of course, the thickness of the panel that is going to be cut.

Laser and MDF: an example of success in the industry of packaging

The best results of CO2 laser cutting on wooden products are achieved on the so called engineered woods. Those derivatives of wood include products such as plywoods, laminated woods and medium-density fibreboard or MDF.

Not too long ago, the operations that could be achieved on such materials were scarce, due to intrinsic properties of them. All engineered wood are composite materials, made from fibers of chips of wood pressed together. This features made them unsuitable for accurate machining operations, especially at a small scale. That’s why they’ve long been overlooked as engineering material.

CO2 laser cutting made those materials suitable for a new set of applications. An example of this can be seen in the packaging industry.

The construction of packaging products is a very challenging business. A good packaging has to be tough, light and attractive for the customers. But how to achieve all those contrasting needs? Thanks to CO2 laser cutting, the packaging industry introduced new materials for the creation and design of packaging. This is the case of boxes, crates and cases made from laser cut MDF panels.

MDF provides the same toughness and performance of solid wood but at a lower cost. Those characteristic make MDF a perfect material for the design and engineering of packaging products like boxes, crates and cases of various kind. A CO2 laser is able to easily cut the panel in MDF in all desired shapes and dimensions. It is possible, for instance, to produce the various components to assemble boxes and crates. In this way it becomes easier to create containers of every kind and dimensions, that can be used to protect delicate products like fruit from the risks of damage during shipping and transportation.

This is only one example of the many possible applications of CO2 laser cutting for wood. The introduction of such a technology affected many industrial sectors anche the packaging industry is only one of them.

It might also interest you: CO2 Laser: a new technology for the fabrication of corrugated fiberboard and cardboard

Laser engraving is one of the many applications of CO2 lasers. This process uses the energy delivered by the laser beam to mark the surface of a material. In the last decades, laser engraving proved to be an effective and efficient tool for the manufacturing applications, especially for the fashion and decorating industry.

The variety of materials that can be engraved is wide and includes either natural and synthetic materials as well as metals. Wood, paper, cardboard, plastic and plastic films or rubber are very well suitable for CO2 laser processing. Those materials absorb very well the specific wavelength of CO2 lasers. This means a greater energetic efficiency of CO2 laser light.

Thanks to this feature, CO2 lasers are particularly suitable to sectors like the fashion industry. This trade largely handles organic materials like natural fiber tissues or leather: CO2 laser engraving proved to be an economically efficient and powerful tool for the decoration of fashion goods and accessories.

The decoration of leather, both natural and synthetic, is one of the branches that have benefitted the most from the introduction of laser as a processing tool.

Leather and CO2 laser engraving

The traditional approaches to leather crafting involves the use of hand tools or physico-chemical processes. Engraving the surface of a piece of leather is a matter of craftsmanship and perseverance. Those methods are not suitable for today’s needs of mass production. They are very slow and time-consuming: leather is a flexible but tough material and thus operations such as cutting or engraving take a lot of effort, expertise and time to be carried out properly.

The introduction of laser has significantly improved those drawbacks of traditional leather decorating techniques.

CO2 laser engraving of leather is based on the energy developed by a CO2 laser focused on the surface of the material. The high density thus obtained, produces the immediate sublimation of a shallow layer of material, leaving a mark on the surface.

Those marks have some great qualities: they are permanent, sharp and very accurate. They are also immune to wearing, scratching or fading because of light or mechanical aggression.

As all laser applications, the whole process is controlled by a software. A typical laser engraving leather machine is composed of three components:

• a CO2 laser source. El.En. Blade RF Self Refilling is a perfect example
• a laser scanning head. It can be boiled down to three main components: a X axis galvanometer, a Y axis galvanometer and a z axis actuator that dynamically adjusts the focal length of a lens. The purpose of the scanning head is to deflect the CO2 laser beam so as to to keep it always focused on the working area
• a software. It translates the design developed by the operator into the a that the laser beam will follow.

Thus it is possible to create any model on the software and then transfer it onto the surface.

The advantages of CO2 laser engraving on leather

With the help of the software, it becomes possible to accurately control parameters such as the speed, power and intensity of the CO2 laser beam. Depending on those parameters, laser engraving allows a virtually infinite variety of effects on leather.

The advantages of such a feature are remarkable for the general leather engraving process:

• A CO2 laser system is flexible:it is possible to rapidly develop and test new design prototypes and try out textures, patterns and other effects
• The use of nesting software allows to automatically find the most efficient laser engraving pattern, thus minimizing the production of scraps and wasted material;
• The controlling software is also able to optimize the efficiency of the CO2 laser machine. For instance, by identifying shared contours that can be cut at once;
• It is possible to reproduce the same design over and over without minimal or no differences, resulting in constant quality over the time.

Those aspects of CO2 lasers make them an attractive tool for the producers of leather goods, especially for those operating in the fashion and decorating industry. The laser is a flexible and efficient device. Its possibilities are infinite, all to be explored and tested. It allows innovation and originality, freeing the designer from the constraints of traditional leather engraving techniques. And, undoubtedly, this is a considerable benefit that CO2 lasers can offer to the fashion industry, constantly driven by innovation and always in search of original designs.