One of the most frequently asked questions we receive on this blog is about the difference between fiber optic Lasers and CO₂ Lasers. These are the two types of lasers most used for industrial application. If compared to fibers lasers, CO₂ lasers have numerous advantages that fiber lasers don’t have.

Both the CO₂ laser and the fiber optic laser work in the infrared spectrum. There is however a substantial difference between them.

A typical fiber optic laser works at a wavelength of 1.064 micrometers. It is used in very specific sectors, such as metal cutting, which require a very high concentration of power.

The typical wavelengths of our CO2 lasers are 9.3, 10.2 and 10.6 micrometers. This flexibility makes it possible to work with different types of material. The area of application of carbon dioxide laser is not limited to metals only but can also be applied to wood, acrylic, glass, paper, fabric, plastics, films, leather, stone, etc.

Thanks to this feature, the use of CO₂ laser has spread to a wide variety of industrial applications in recent years. Its flexibility and versatility make CO₂ laser the most used type of laser. It offers both high quality and the ability to satisfy most customer requests.

Versatility is not the only selling point of the CO₂ laser has over fiber laser. Here are other features that make the CO₂ laser the ideal choice for most applications:

• More precise when cutting thick materials: the CO₂ laser operates at a wider wavelength therefore it is more suitable than the fiber optic laser for processing thick materials. It also leaves a much smoother finish
• Uniform quality: the quality is the same on all materials whilst with the fiber optic laser it can be slightly different depending on the density of the processed material
• Straight line cutting speed: a CO₂ laser is faster at cutting in a straight line, and also has a faster penetration time once the cut has been initialised
• Possibility of control: the CO₂ laser can work with materials of different thickness. The power and duration parameters of the laser beam can easily be adapted to the technical specifications of the material.
• Greater safety: the light emitted by the CO₂ laser does not have a blinding effect. It is therefore must simpler to make the production line safe.
• Ease of implementation: the CO₂ laser makes it possible to create light and compact machines, capable of satisfying all production needs, even those of smaller dimensions.

CO₂ laser: versatility and reliability

On the basis of what we have written, it is clear that the choice between fiber laser and carbon dioxide laser depends on the type of application, i.e. the quality of the material and the technical requirements of the production.

If the fiber laser is particularly effective on metals, the CO₂ laser offers much more versatility and control. It allows to process most plastic materials and all organic materials but it can also be used on metals for surface treatment and laser marking operations. It also has a long history of industrial applications, making it a reliable and safe tool.

The CO₂ laser is therefore the best choice in most material processing industrial applications. If you have a process in mind that could be carried out using a CO₂ laser, contact us, and we will be happy to find the application that best suits your needs.

The use of laser CO2 in food production processes has become a well accepted trend. Laser is often used to replace labeling processes or the printing of expiry dates, identifying codes and other distinguishing marks on food products. Markings on cheese or fresh products (such as fresh fruit) are some examples of laser use we have already covered in previous articles.

Another process that can be successfully achieved by laser is the marking of chicken eggs.

The traditional method used for egg marking is ink printing.

Because eggs are fresh products, it is fundamental that information such as laying or expiry date be clearly visible on each item. This data  helps the consumer to evaluate the freshness of the product, making egg consumption safer.

Ink marking can be inconvenient because:

• the ink can contain harmful substances
• the markings are not always readable
• the ink needs to dry, slowing the production line
• more resources are used

Laser marking makes it possible to overcome these obstacles. Let’s see how the process works.

A laser marking system is composed of three elements: a control software, a CO2 laser source and a galvanometric scanning head.

In this application of laser marking, the source is used in pulse mode. This mode makes it possible to reach high peaks of power for a very short amount of time, instantly removing a tiny portion of the surface area of a product.

The scanning head has a double function: it moves the laser beam over the surface on the X and Y axes and it keeps it focused on the right surface area.

The control software’s job is to coordinate the action of the laser source and the scanning head. It makes sure that the laser follows the pre-established path and that the power is regulated properly for the desired effect on the surface.

The advantages of a pulsed laser marking system are many:

• the markings are permanent
• potentially hazardous substances aren’t used
• the process is notably faster than ink marking

It has been demonstrated that the markings are superficial and in no way damage the egg as only around a fourth of the eggshell’s thickness is marked.

This technique is perfect not only for alphanumeric codes, but also for logos, pictures and other types of graphic signs.

Until recently and partly still, industrial processes were focused on mass production. This encouraged a tendency to standardize products and processes, to reduce the number of possible customizations and to maximize the number of pieces produced thus increasing the company’s profit.

A production paradigm of this kind could work as long as the relationship between producers and customers was controlled by one side. The market bought what the producer offered. Recent technological advances, combined with changes in the market and client requests, have brought about a paradigm shift.

Highly customized forms of production, which were previously economically unsustainable, are now possible thanks to the use of technology and digital manufacturing processes.

Laser is the cornerstone of this change and has revolutionized many sectors allowing the reduction of production costs, the speeding up of production and the possibility of creating customized products on a mass scale.

This last statement might seem like a paradox, but to fully understand its scope, one must change the traditional way of looking at industrial production processes.

Think like a laser

The acquisition of a laser system is not just the acquisition of a new machine. It also requires the adoption of a new way of thinking about production. It becomes necessary to know the advantages that laser offers, exploit its strengths and use it productively and economically.

Let’s go over laser technology’s strengths point by point: versatility, precision, cleanliness, speed and lack of contact.

Versatility

Laser is versatile on many levels. First, CO₂ laser can work with a wide range of materials. This type of laser gives its best results on materials of organic derivation (wood, paper, cardboard, leather, fabrics, acrylic plastic materials, etc.) on which it can effectively perform any type of processing. On the other hand, CO₂ laser has a more restricted range of applications on metallic materials, particularly in the field of laser engraving and marking or for surface treatments such as paint removal.

Precision

The very nature of the laser beam makes it a highly controllable tool. Its parameters and features are easily managed with a software, and they can be set according to the desired result. This feature of laser has paved the way for precision machining and made it possible to create perfectly calibrated pieces based on the functions for which they were created.

An example of this type of application is the perforation and cutting for food industry. For this particular type of packaging, holes are made on the surface of the plastic film to improve the breathability of fruit and vegetables. The perforations vary depending on the product’s characteristics.

This is just one example of the applications made possible by laser technology. Other examples include the perforation of leather for car interiors, the manufacture of pipes for irrigation, the microperforation of instruments for the health sector.

Cleanliness

Of all the machining processes based on the removal of material from a workpiece, laser is the one that produces the least residue because the material is removed by sublimation. Even the processing waste (i.e. the parts of unused raw material) can be reduced thanks to nesting, which is managed by a special software.

Computer control makes it possible to make the most of the work surface. In most cases, one can obtain more finished pieces from the same material using this technology than with traditional methods. In this respect, laser represents a leap in quality if compared to other processes based on chip removal, or on the use of various types of abrasive fluids.

Moreover, the need to remove production waste is reduced. The laser beam concentrates high energy on the processed material which, undergoes chemical-physical alterations that cause its instant removal.

This feature makes laser ideal for all the industrial sectors where the absence of processing waste and a clean production environment are key. Consider, for example, the field of electronics, the medical device sector, and the packaging sectors.

The absence of waste and other residue also has an economic advantage: in fact, the cuts made with the CO₂ laser do not need further finishing. They are performed without leaving the slightest trace of material behind. Each piece therefore takes less time and money to produce.

Speed

In industrial processes, the speed at which work is performed is a fundamental requirement.

Laser is capable of performing work at a very high speed. This feature is particularly evident in the execution of complex design operations.

Processes such as the engraving of barcodes and identification codes, the decoration of fabrics, or the cutting of complex shapes are carried out practically instantaneously by a laser beam.

But even slow and expensive processes such as fabric finishing can be effectively replaced by a CO₂ laser. A previous article explored the finishing of denim fabric through laser scanning processes. In the past, the discoloration of jeans was performed using very slow chemical processes, which were expensive in terms of resources and extremely polluting.

The integration of laser in the production chain of these products has made it possible to significantly speed up the production process, achieve considerable savings in terms of resources, as well as reduce the ecological footprint.

Lack of contact

Laser is a non-contact process, a feature that comes with many benefits.

Firstly, tool wear is limited. As a result, maintenance costs are reduced. The laser beam, (the instrument that physically performs the processing), emits a coherent and focused beam of light. Since there is no mechanical contact between the tool and the material, it wears less.

Of course, even a laser source needs routine maintenance. The laser-producing medium, CO₂ gas, is consumed over time. The self-refilling technology developed by El.En. for its laser sources has made it possible to greatly reduce maintenance. The gas can be refilled in-house which reduces the machine’s periods of inactivity.

The lack of mechanical limitations on laser movement, the small diameter of its radius and the possibilities offered by numerical control combine to give very high tolerances during production. Engraving or cutting complex shapes become extremely simple. This is a feature that makes laser an ideal choice for all the sectors that use design to get a competitive edge, such as fashion.

It is clear that the introduction of laser in the production process is advantageous for all the applications where personalization, speed and production flexibility are decisive.

Companies that deal with productions with a high level of customization, which need precise processing, which must respond to a market with multiple demands, can compete in a cost-effective way with other companies that make economies of scale their strength.

Whatever your application is, please, contact us using our form. We will be glad to support you with our experience!

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.

Plastic is one of the best suited materials for CO2 laser cutting. Polymer laser cutting is a very efficient and effective industrial process. Among all the plastic polymers that can be processed by CO2 laser, polyethylene is one of the first in terms of frequency of use. Polypropylene has an excellent laser energy absorption capacity which makes it suitable for all types of applications ranging from drilling to welding.

Polypropylene: characteristics and uses

Polypropylene is a thermoplastic polymer obtained from the polymerization of propylene.Its main feature is that the molecules making up the polymer can be arranged in an ordered or random way. In the first case, polypropylene takes on the characteristics of an isotactic polymer.

This configuration is the most commonly used commercially since it gives the material excellent chemical, physical and mechanical characteristics.

Polypropylene has a high heat resistance (greater than polyethylene), good elasticity, rigidity and the ability to absorb shocks without breaking. It also has a low density, (which makes it light), a high insulating power and good resistance to oxidizing and chemical agents.

Finally, polypropylene can be processed in a variety of forms: injection molding, thermoforming, extrusion for the creation of textile fibers.

Given these characteristics, polypropylene has found a myriad of applications in every field. One can argue that there is no industrial sector that does not make use of polypropylene in some shape or form.

Here is a list of the objects that are most often made with this material:

• Packaging, labels and containers
• Kitchen items such as dishes and food containers
• Sportswear
• Components for automobiles
• Bags,
• Sanitary objects
• Electronic object components

Can you cut polypropylene with laser?

Yes, of course. Polypropylene laser cutting is a very efficient process since this polymer absorbs the infrared wavelength of CO2 laser very efficiently. With laser, making cuts or drilling holes on polypropylene is very easy.

On a macroscopic level, laser works as a cutting blade. The cut has a smooth and well-finished straight edge with no presence of burns or charring. Burr formation or cutting irregularities due to the presence of residues are also very limited. The high energies produced by laser not only melt the plastic, but makes it evaporate by sublimation.

The quality of the cut is directly influenced by the laser power, the cutting speed and the thickness of the material. In general, a medium-power CO2 laser source is sufficient to perform most of the processes needed in polypropylene applications.

Furthermore, the quality level is also influenced by the wavelength used. For this type of material our team of El.EN engineers have devised a specific laser source: BLADE RF333P.

This tool is very well suited to label cutting applications which use the kiss cutting process. A fundamental characteristic of this process is the variation in wavelength absorption related to the type of plastic film used.

In addition to simple cutting, polypropylene also lends itself well to laser kiss cutting operations, a process used mostly in adhesive production processes. Drilling polypropylene is also a suitable application, especially useful in the fabrication of plastic bags for modified atmosphere packaging.

Implementing a laser system for polypropylene cutting

The process of laser cutting polypropylene has many advantages: it allows you to perform complex, precision machining with great speed. It is also a very flexible system, which lends itself to numerous applications.

In addition to cutting, polypropylene responds very well to other laser processes, especially drilling (perforation), marking and engraving, welding. The same laser source can carry out all these processes.

If you work with polypropylene and would like to shift to CO2 laser technology, contact us. We would be happy to help you find the most suitable laser solution for your needs.

Can you laser cut PTFE (Teflon)? The answer is yes. PTFE can be successfully laser cut, marked or engraved. In this article we describe in depth what laser processing techniques can applied to PTFE and the results that can be achieved.

PTFE also known under the trade name of Teflon® or Algoflon® is a synthetic polymer used in many fields. The acronym stands for PolyTetraFluoroEthylene (PTFE). It is a plastic material, usually white in color though it can be colored black with additives. It can be used alone or in combination with other polymers.

PTFE belongs to Perfluorocarbons, a class of polymers composed mainly of fluorine and carbon chains.

Their chemical composition offers a wide range of properties which include:

• Non-stickiness
• Waterproof
• Resistant to chemicals
• Resistant to fire and high temperatures
• High insulating power
• Smooth

The applications are numerous. It is most commonly known for its use as a anti-coating material for kitchenware. But PTFE is also used to create gaskets, insulating tapes and in any other place where a component that reduces friction and resists corrosive agents is needed.

The fact that it is mainly composed of carbon makes it perfectly compatible with the CO2 laser wavelength. Laser cutting, perforation, marking and engraving on PTFE is easy and gives excellent results.

The interaction between PTFE and CO2 laser

The material interactions between PTFE and CO2 laser depend on the high insulating power of PTFE.

In general, when the laser beam reaches the surface of a material, it concentrates a very high energy in a single point. According to the characteristics of the material used, different chemical or physical transformations occur.

In the case of PTFE, the energy generated by the laser breaks the molecular bonds of the fluorine and carbon chains causing the chemical transformation of the material (laser marking) or its removal (laser cutting and engraving processes).

Being a material with excellent insulating properties, PTFE absorbs heat at the point of contact with the laser, without dispersing it in the surrounding area. It also has a high melting point. Both of these characteristics highly influence the laser’s behavior.

The poor thermal conductivity combined with the high melting point mean that the HAZ (Heat-Affected Zone) is very reduced. It is limited to the point of contact between the laser beam and the material.

As a result, laser processing on PTFE is very precise and clean. The chances of accidentally damaging the material or creating blackened or burned areas are very low. The fact that PTFE absorbs CO2 laser energy very well also makes processing very efficient in terms of speed.

Laser cutting Teflon

The PTFE laser cutting process works this way: the beam is used to remove material along a predefined cutting path. The removal of the material occurs by sublimation: the energy generated by the laser is concentrated in a very small area, and it is precisely the high energy density that causes the instantaneous passage of the material from the solid state to the gaseous state.

Laser cutting is used in many activities such as creating openings in a material, cutting out shapes from a sheet of material, making pieces from a matrix.

The peculiarity of laser cut PTFE is that its cutting edges are clean and perfectly finished and the obtained piece therefore does not require any further work. Laser cutting makes it possible to follow highly complex cutting paths.

PTFE Laser drilling

Laser drilling is a variant of laser cutting. It is also know as laser perforation.

In this process the laser is used to create a hole in a sheet of material, just like a mechanical drill would do. Laser perforation doesn’t suffer from the same limitation of traditional mechanical processing.

Microscopic holes can be created with laser technology. They can range in size from a fraction of a millimeter to the maximum area the machine’s design characteristics allow.

In addition, with laser technology, all the processing parameters (the inclination of the walls of the hole, the taper, the depth and density of the holes on the surface) can be controlled with great precision. It is possible to create pieces with all the characteristics best suited to the function they must perform. In the case of a filter, for example, holes can be created with precise dimensions, shape and arrangement.

PTFE Laser marking and engraving

PTFE also lends itself well to laser marking and engraving processing techniques. Marking and engraving are typically used to emboss logos, alphanumeric codes, barcodes or QR codes and various types of information on a particular material.

Both processes are based on the interaction between the laser beam and the surface of the material.

In laser marking, a chemical transformation of the material takes place and a the material is marked on the surface. In laser engraving, the material is removed. So, while laser marking takes place on the surface, in laser engraving the laser creates a groove in the material and the mark is carved into its surface. The choice of one process over another depends on the type of application or material being used.

On white PTFE, for example, laser marking gives poor results because the mark does not have high contrast to create a sufficiently visible mark. As mentioned, PTFE has a high melting point, so it is difficult to create burn marks.

Oppositely, on black PTFE, marking is more successful. At high temperatures PTFE expands and gives white marks which have a high contrast with the surrounding black background.

Laser engraving, on the other hand, can be performed on any type of PTFE with optimal results. As we have said, PTFE is an excellent absorber of the CO2 laser wavelength, but also a bad conductor of heat. This ensures that the area affected by heat is limited to the point of interaction between the laser and the material, resulting in a very precise and clean engraving.

Write to us to know more about how to process PTFE with CO2 laser.

Each laser application has its own particularities. There is no rule that applies to all circumstances and all materials. To find a solution that suits your needs, contact us, and we will be happy to find the best solution for you.

Laser wire stripping is the process of removing all or part of the insulating material that covers electrical cables. In other words, it is the process used to uncover the metal core of the cables. It is typically done at the cable’s ends to make connections possible, but it can also be done in various ways along the cable.

Laser stripping’s main feature is that the laser selectively intervenes on the insulating material without affecting the cable’s metal core. This is a significant advantage over traditional stripping techniques. The high quality and precision of the laser striping process has made it a widely used technique in high-tech sectors.

Not surprisingly, the idea of ​​using lasers to remove the insulating layer of electrical cables was born in the aerospace sector. In the 1970s, NASA needed to find a solution to strip the thin Space Shuttle cables. The stripping tools used at the time did not guarantee the quality and precision necessary for an application of that type.

Traditional wire stripping methods and their drawbacks

The first is the mechanical method, which is the most widespread. In this process, blades are used to cut the electrical cables’ sheathing.

This method has many drawbacks:

• to achieve accurate results, the process becomes extremely slow
• each type of cable requires a dedicated tool
• the tools require maintenance to remain effective

The risk of damage, for example notching the cable, is one of the main risks of this technique. To solve this problem, manufacturers have produced oversized cables, so that any loss of metal would not reduce the functionality of the cable.

While this may be a solution for low-tech industries, oversizing cables is not a suitable solution for others.

In the aerospace sector, for example, weight containment is essential. Cables are designed to be very thin so that they weigh as little as possible. This means that any damage to the cable could cause it to malfunction and lead to accidents.

In addition to the mechanical method, peeling can be performed with a chemical or a thermal process.

The chemical process uses corrosive substances such as sulfuric acid to dissolve the cable coating and expose the conductive material. The disadvantage of this technique is that it is not easily controlled and is also polluting.

The thermal process uses a heat source to remove the coating. This method, however, can leave residual coating material on the metal core which would therefore have to be subjected to further processing.

Laser stripping overcomes all the previously mentioned drawbacks. It is therefore not surprising that it has established itself as the method of choice for high-tech applications.

Why laser stripping works

In most cases, the material that coats electrical cables is some kind of plastic polymer while the internal core is made of metal, very often copper. Laser technology has the ability to select only the coating’s polymers without modifying the conductor in any way.

This behaviour can be explained by the way laser radiation interacts differently with different materials.

CO2 laser emits radiation at a wavelength of 10.6 micrometers, that is, in the far infrared [far-IR] region. Polymers absorb this radiation very well while copper reflects it almost completely, without undergoing alterations.

The advantages of laser stripping

Laser stripping offers several advantages over traditional methods:

• flexibility: it is effective on almost all polymeric materials with which electrical cables are coated
• precision: it is a non-contact process, which makes it able to work on very tight tolerances and to carry out processes that would be impossible with traditional methods
• effectiveness: since laser is reflected by most metals, the process ends with the removal of the polymer without requiring any further processing

What are the different types of laser stripping

In laser stripping, the laser can perform 3 basic operations:

• laser cross cutting: the cut is carried out transversely to the cable in order to allow the removal of excess material
• laser slitting: the cut is made lengthwise. Typically this process is performed when a longer portion of cable needs to be removed and is used in conjunction with the cross cut
• laser ablation: the laser passes over the surface several times until the coating is completely eliminated. This technique is mainly used when the conductive material is immersed in the coating (otherwise known as bonded wire).

Alongside these basic operations, laser technology makes it possible to perform advanced processes such as the partial and targeted removal of the coating with the creation of windows or the removal following certain patterns. All these applications can’t be done with traditional mechanical methods.

As is often the case with lasers, the possibilities are endless.

How a laser stripping system is made

A laser cable stripping system can be implemented in various ways and with various technologies.

The most effective is certainly galvo-scanning. In this application, a scanning head is used to move the laser beam and then focus it on the work surface.

The whole system is controlled by a computer which coordinates the operation of the CO2 laser source allowing the laser to follow the pre-defined cutting path.

Implement your own laser wire stripping

Laser cable stripping lends itself to many applications. It is ideal for high-tech sectors that require great precision during the processing phase. One of the applications, for instance, is magnet wire stripping with laser.

Don’t hesitate to contact us. Our staff would be happy to advise you on the best laser solution for your needs.

In recent years, CO₂ lasers have increasingly been used as work tools in the abrasive material sector. CO2 laser technology can perform advanced processes which are well-adapted to new generation products (suitable for the most innovative processes and sectors).

The production of abrasive discs is a perfect example of this type of production. One of the most appreciated features of an abrasive disc is its ability to facilitate the elimination of debris from a work surface. In order to obtain the desired effect, there are holes on the disc to facilitate the expulsion of debris. The holes need to have a certain size, be evenly and precisely distributed on the disc, and have a specific surface density to be effective.

Nowadays, in the abrasive disc production sector, the most used tools are mechanical ones like blades and dies. The main advantage of these tools is that they are cost effective.

However, the production of abrasives with dies also has several disadvantages:

• Limited accuracy. Due to technical limitations, blades and dies cannot perform work under a certain diameter, with narrow spacing or in special arrangements. Therefore abrasives produced with mechanical methods can hardly reach the optimization levels required by the most advanced applications.
• Deformed surfaces. The cutting process is achieved through mechanical contact. This exposes the processed object to the risk of deformation. The disks produced from a matrix sheet are often deformed by the pressure of the dies. The disc acquires a concave or convex shape which reduces the usable abrasive surface and therefore makes it less effective
• Tooling costs are increased. Cutting tools get worn quickly by their application to abrasive materials. These tools need to be replaced frequently which increases the overall production costs.
• Lack of adaptability. Most shape variations and modifications require the acquisition of different cutting tools.

Laser technology for abrasive materia die cutting

The CO₂ laser is an optimal production medium for flexible abrasives since it has none of the previously mentioned shortcomings. In recent years the cost oflaser material processing has lowered, and therefore become much more used the abrasive material sector.

Laser’s main advantages in cutting abrasives are:

• Easy to calibrate. Characteristics such positioning, distribution, and the diameter of the holes (which can be very small) can be calibrated with great precision. Laser is therefore suitable the advanced, high precision processes required by the market
• No risk of deformation. Laser is a non-contact process therefore the risk of the material getting deformed are close to none. Abrasive discs produced with laser are much more efficient than abrasive discs produced with mechanical methods
• Low maintenance costs. Lasers used for the processing of abrasive materials are not subject wear because there is no physical contact between the tool and the material
• Flexibility. Laser technology makes it possible to totally or partially modify the shape to be cut by simply making changes to the processing file on the software. This method saves on time and the cost of procuring a new mechanical tool

A very promising sector

These are just some of the possible laser applications in the field of abrasives, and each has its own characteristics and needs. Laser processing of abrasives is a very promising field of application. Our CO₂ laser sources combined with our galvanometric scanning heads are ideal for this type of application: powerful, effective and precise, they can be easily integrated into existing production systems or to new digital converting machines as well as to an industry 4.0 production chain. Contact our El.En.experts to answer your questions and find the right solution for your needs.

Laser marking is one of the most common industrial processes. In its broadest sense it consists in using the laser beam to create marks on the surface of a material.

The process is simple: the laser heats a layer of material, instantly vaporizing it. The visual contrast between the part that has been processed and the rest of the material is the engraving.

CO2 lasers are the ones most used for this type of application. They are highly versatile and suitable for laser marking applications in virtually any industrial sector.

Laser marking lives under the umbrella of galvo scanning applications. In this family of applications, a scanning head is used to focus the laser beam on a surface. In other words, the scanning head moves around the laser beam (which otherwise would travel in a straight line) towards the points that need to be processed. It does so through special mirrors connected to galvomotors.

The scanning head is key in galvo scanning, and it is what gives this application great flexibility. The scanning head makes it possible to use the laser to impress any type of sign on a surface: from simple alphanumeric codes to complex images, for the impression which using laser is a winning strategy.

Compared to traditional systems, laser marking applications have several advantages:

• cleanliness and speed
• precision
• versatility on materials
• possibility of automation
• respect for the environment
• durability over time

Materials

The versatility of the CO2 laser allows laser marking to be applied to a wide range of materials. This family of lasers interacts very well with carbon-based materials such as thermoplastics, wood and its derivatives, fabrics and organic materials in general. Here is a list of the most used materials in laser marking applications.

Wood and derivatives

Wood and its derivatives are used in a large number of industrial sectors. Whether it’s packaging or signage, laser marking can be used to apply various types of signs or decorations. Regardless of the desired effect, the process will be fast and effective.

Plastic

Plastics and thermoplastics are today widely used for an infinite number of applications, especially in the packaging industrial sector. Acrylic, polyethylene, polyamide and similar plastics undergo laser marking very easily with excellent results.

Metals

Laser marking is very effective also on metals. Though the CO2 laser is not the most suitable for cutting metal, it is perfect for modifying its surface because it produces very sharp and clear incisions.

Fabrics and leathers

Laser marking is perfect for processing fabrics and leathers. Both natural and synthetic fibers interact very well with the CO2 laser.

Laser can be used on these materials for numerous applications ranging from finishing fabrics to decorating garments. The main advantage of laser marking for fabric is that it considerably decreases the use of water and chemicals, thus reducing the negative impact the textile sector has on the environment. Today, the majority of laser marking applications on fabric are on denim.

Glass and ceramics

Laser marking lends itself well to the decoration of objects made of glass and ceramic. In this application laser marking is mostly used for the decoration of finished objects. Glass objects can even be decorated from within. The laser’s scanning head manages to reach the inside of the glass object, creating a three-dimensional image.

Biologic materials

The application of laser marking on biologic material is a recent thing. These materials are rich in carbon and therefore respond very well to the wavelength of the CO2 laser. The food industry has finally caught on to the benefits of the laser process that is very useuful for this sector thanks to its sterility.

Industrial sectors

The fact that this technology offers extreme flexibility in terms of choice of processed materials multiplies laser marking applications and opens it up to numerous industrial sectors. Indeed, it can be said that virtually any sector that uses compatible materials can benefit from laser marking applications. Here are some examples.

Automotive

In the automotive sector, laser marking can be used for a great number of purposes. An example is removing polyammid sheathing wrapped around the wires used in motors. Thanks to laser this process can be greatly streamilined, allowing for great economies in the production process.

Due to the flexibility allowed by the laser and the very low cost of the single machining cycle, laser marking lends itself very well to taylor made applications. From a commercial point of view this means that it is also possible to offer services such as interior customisation at a very low price and with a great economic return.

Labeling and packaging

The packaging sector is perhaps the one in which laser marking has most applications. Personalization and automation rule this sector so that the full potential of laser can be fully exploited. There are different types of applications that range from decoration of packaging to the engraving of identification codes and logos.

Laser labeling of food products is becoming increasingly popular. This application also has a name, natural branding. Laser labeling consists of replacing the self-adhesive label applied to products with a label engraved directly on the product by laser marking.

This labeling method makes it possible to obtain 100% compostable products and to reduce the use of packaging. On the one hand, adhesives composed of chemical substances are not used, and on the other hand, the consumption of potentially polluting plastic materials is reduced because the waste of the adhesive label substrate, usually not visible to the consumer, is eliminated. Laser labelling has been successfully applied both on fresh products and on cheeses and cold cuts.

Display panel production

The production of information panels is another great field of application for laser marking. This application is very efficient on the most commonly materials used in this industry (acrylic plastics, aluminum, glass and wood).

Laser marking makes it possible to design complex logos and to engrave writings of any type and length.

In contrast to traditional techniques such as screen printing or engraving, laser marking is indelible and therefore has a considerably longer life. The production process is also much faster and cleaner.

Textile, fashion and interior design sector

In recent years designers from around the world have discovered laser marking. Laser makes it possible to go directly from the design phase to the production phase.

This feature makes it ideal in areas where creative experimentation is a competitive advantage.

In fact, creating prototypes and experimenting with creative solutions is much easier if you follow a digital production paradigm (of which laser is part). It’s a quick step from the design on the computer to the finished product. Furthermore, laser can offer the designer more freedom from physical limitations imposed on his design by means of production.

For these reasons, laser marking is increasingly used in creative sectors. As we’ve seen before, laser can be used in the textile sector for the finishing of fabrics (e.g.: the coloring of jeans), but also for the creation of ornamental motifs on fabrics or both leather and faux leather for the clothing or interior design sectors.

Even wallpaper, curtains and carpets lend themselves very well to the application of decorative patterns by laser marking.

Another application in the interior design sector is the decoration of ceramic tiles. Original and complex patterns can be applied to ceramic tiles or other objects at a very low cost.

What is your application?

As seen in this article, laser marking can be applied to many areas. This technology grants important advantages in terms of speed and efficiency of the production process. It allows you to respond promptly to the demands of constantly evolving markets.

At El.En., we have a long experience in the production of CO2 laser systems for marking. Do you have an application in mind that could be implemented with laser technology? Let us know and we will be happy to find the solution that best suits your needs.

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.