The laser scanning heads are a fundamental component of the galvo systems for laser cutting and marking. These devices deflect the laser beam coming from the source and move it along the X and Y axes according to the operation required.

The components of a galvo head for laser

A scanning head is made of different components.

Galvo mirrors

Mirrors mounted on galvanometric rotary motors deflect the laser beam. These motors transform electrical voltage into angular movement.

The mirrors, mounted perpendicularly on the engines, move the laser beam along the X and Y axes according to the input received from the motor.

The big advantage of these devices is that they can reach a very high acceleration and speed of movement.

The size of the mirror depends on the laser beam. As the diameter and the power of the beam increase so must the diameter of the mirror. The same size in turn influences the acceleration and speed of the engine’s angular movement. The smaller mirrors reach higher accelerations than the larger mirrors.

In the range of El.En.’s products there are galvanometric mirrors for different applications. Find out more about our complete 2-axis CO₂ laser galvanometer mirror line on our website.

Z-linear optics

Galvo mirrors are not the only components of a scanning head. The z-linear lens, which focuses the laser on the work surface, has an important role to play too.

To focus the laser beam and get it to work optimally, the focal length of the lens must vary based on the distance between the scanning head and the point it needs to reach on the surface.

The z-linear lens changes the focal length in real time and maintains the laser beam in focus regardless of its distance from the workpiece.

The control software

The control software makes sure that all the moving parts of the scanning head stay coordinated.

It transforms a vector file (the place where the work to be performed is described), into a path for the laser beam. The control software makes the galvo head and the laser source work together to achieve the desired result.

What processing can be performed with a laser galvo head?

As previously mentioned, the laser galvo heads are mainly used for cutting and laser marking.

Laser galvo cutting

Galvo heads make it possible to reach high processing speeds for cutting applications. Galvo heads are perfect for the processing of thin materials such as paper, cardboard and plastic film.

The head can cut out any shape quickly.

Some of the industries that benefit most from the use of galvanometric motors are the adhesive label sector that use kiss-cutting applications and the packaging industry that uses galvo-laser applications to make products with advanced features.

Galvo laser marking

The main marking applications include the marking of various types of alphanumeric codes, such as barcodes and QR codes, and the engraving of ornamental motifs for decoration.

Laser marking can be performed on different materials such as thermoplastic polymers, wood, fabrics, leather, metals, glass.

In the case of transparent materials it is also possible to perform the impression of three-dimensional figures inside the object.

The advantages of laser galvo heads

Laser applications get many advantages from the use of galvo heads:

• Speed ​​- The galvanometric motors reach very high angular speeds. This means that the laser beam moves over the surface of the workpiece with speeds reaching tens of centimeters per second. Thanks to this the productivity of a laser galvo system is very high.
• Integration – Precisely because of this characteristic, galvo laser systems are suitable for integration into larger production flows. A laser galvo system consisting of a scanning head and a laser source performs best when inserted into automated processes. Furthermore, it is compact enough to be easily added to pre-existing systems, giving it an important upgrade without major changes.
• Quality – The laser galvo systems guarantee high quality and detailed results. In marking applications, the scanning head gives the possibility to create a wide range of effects, including the reproduction of a photograph on a surface.

One device, many tools

Scanning heads are a key tool in laser material processing applications. They transform a single beam of polarized light into an instrument with many applications.

To choose the scanning head that is most compatible with the application you need, request the help of an expert. Get in touch with us: our team at El.En. will be happy to help you find the most suitable laser scanning head for your applications.

Laser labeling of food is a recent innovation that makes it possible to reduce production waste by replacing traditional food labels with laser engraved labels. Laser marking of food is suitable for companies wanting to optimize their production process, saving resources and materials while also decreasing their ecological footprint. The possibilities are endless.

In fact, an increasing number of companies have realized that laser techniques are the key to process innovation. In a recent article we discussed the growing phenomena of natural branding, a process in which traditional food labels are replaced by the laser marking of the skin of food.

Fresh products such as fruits and vegetables can easily be marked through a laser scanning head, a low power CO2 laser source and a software that controls the process. This procedure of laser marking permits us to imprint logos, barcodes, and any type of information on different types of food without affecting their quality. The marking does not affect the organoleptic properties of the food – it is a “friendly process” as it only affects the most superficial layer of the skin of fresh products.

However, fruits and vegetables are not the only types of food that can be marked with the CO2 laser technology. Results have shown that even seasoned and semi-seasoned cheese and hams can be marked.

A case study: machine designed to mark seasoned and semi-seasoned cheese.

These seasoned and semi-seasoned products have always been marked through heat methods. Products are marked with their brand and codes that establishes the batch of production, identify the producer, allow to trace back the origin of the product. The easiest system to mark food is to use a metal to impress a brand by burning the surface of the product.

This traditional method, while being inexpensive, is incredibly slow and inflexible. In order to change the codes to be imprinted, a change in the marking tool is needed.

A more efficient way of imprinting information on food is to use the CO2 laser application. The laser allows to mark the surface of these products faster, with higher precision, and in a more secure way. In comparison to traditional ways of marking food, such as marking through means of heat, laser marking allows us to have an extremely precise process: it provides the possibility to adapt all parameters involved to suit the characteristics of the product to be marked. In this way the process of laser marking becomes the more precise way as it respects the unique characteristics of each product.

A system for marking the dairy products may consist of the following elements:

• Completely washable stainless steel structure
• Conveyer belt
• CO2 laser source
• High performance laser scanning head
• Controlling software

The functioning is semi-automated. The system involves the presence of an operator placing the products to be marked on the conveyer belt. The conveyer belt transports the products to the laser processing space, isolated from the outside with doors that can be opened for inspection and sanitation reasons. Here the laser scanning head, controlled by a software, guides the laser beam on the surface of the product, performing the marking within seconds. In a few minutes only, the operator is able to perform the same operation dozens of times.

The advantage of such a system is its flexibility. First of all, the machine is designed to be modular: each module can be replicated and adapted to the needs of the manufacturer. For example, you can install different laser sources for different applications.

Furthermore, the system allows you to change the information you want to mark very quickly. You just have to modify the parameters inserted in the control software to perform a different process.

Laser cleaning is the process of using lasers to remove dirt, debris or contaminants from the surface of an object. It is a process that lends itself to a variety of industrial and non-industrial applications. From cleaning thermoforming moulds to restoring monuments, there is no area where laser cleaning cannot be successfully applied.

In this article, we explain what the laser cleaning process consists of, the principle on which it is based and why it has an advantage over conventional cleaning methods.

Conventional cleaning methods

In the field of industrial production, the maintenance of production tools is essential, particularly in those areas where the quality of production depends on it. In the plastic thermoforming sector, for example, it is essential to always have clean moulds in order to obtain high quality parts. Rust, dust and material residues are among the most common types of dirt that need to be periodically removed.

However, cleaning operations are very costly in terms of resources. The actual performance depends on the type of maintenance required. But in general we can say that cleaning methods are based on the use of chemical or mechanical methods.

In the first case, cleaning is entrusted to solvents, detergents or other chemical compounds that degrade the material to be removed and facilitate its removal. In the second case, systems such as sandblasting or ultrasonic cleaning are used.

These cleaning methods have major disadvantages. They are very polluting because of their use of chemical products and require operators to take special safety precautions.

In addition, physical contact often causes damage to the workpiece which, in the long run, ends up being damaged by the cleaning operations.

Laser cleaning has established itself precisely because it has the advantage of overcoming the main drawbacks of traditional cleaning methods.

Laser cleaning and its advantages

Laser cleaning consists of irradiating the surface of a material in such a way as to remove the surface layer. The technique is based on ablation. The beam concentrated on the material breaks the molecular bonds of the material that needs to be removed. The material evaporates instantaneously with virtually no residue left behind.

Unlike conventional methods, there are no solvents or other additional chemical substances used in laser cleaning, and since it is a non-contact process, there is no abrasion that could damage the workpiece, as the surface dirt is removed without attacking the underlying material.

It is precisely this protection of the material that makes the laser so attractive. The laser allows you to operate selectively on a given material. The laser only removes materials that are absorbed by its wavelength. In addition, each material has different properties and needs a different amount of energy to be removed. This makes it possible to work on materials very precisely, to calibrate the laser extremely selectively so as not to damage the underlying material.

Flexibility, high controllability of the medium and speed are the characteristics that make laser cleaning an extremely effective tool.

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.

What if producers and distributors of fruit and vegetables stop using sticky labels? It’s not phantasy but reality: with laser food labeling, labels can be written directly on the skin of a product by removing the superficial layers of the skin itself. An innovation beneficial for the environment and for the consumer. In this article we describe you this processing technique and we present you a case study where we describe how we created an automatic laser system for the labeling of apples. If you already know what natural branding is, you can jump to the case study.

First priority: reducing waste

Recent years have seen the development of a greater sensibility towards the environmental impact of the production processes. Manufacturers are trying to streamline the use of resources and materials, switching to greener ways of producing goods.

For the packaging sector this meant an overall reduction of the materials composing the packaging products: paperboard boxes, rolls of wrapping paper and plastic films are being supplanted by their biodegradable equivalents or they are simply being discarded.

Quite revealing of this trend is what happened to the most simple and traditional packaging product: labels.

CO2 laser labeling? That’s natural branding!

The phenomenon has been called “natural branding” and it especially concerns the packaging of fresh fruits and vegetables. Simply put, natural branding is to replace plain physical labels, sticked on the surface of fresh fruit and vegetables, with “natural” labels, obtained through laser marking.

This is only one of the many applications of CO2 lasers, a technology that demonstrates, again, to be a green process. In fact, producing a mark directly on the skin of produces results in reducing the consumption of materials such as paper and plastic and thus in a smaller environmental footprint of the packaging process. A CO2 laser let you engrave to engrave a lot of information: traceability codes, logo and brand of the producer, expiration dates. All this pieces of information were usually printed on traditional labels that were sticked on the surface of produces.

This laser labeling system is very advantageous for the whole packaging process and for the environment as well: a smaller energy consumption, the reduction of potentially polluting materials, a higher speed of execution. A perfect tool for all the manufacturers aiming at a greener production process.

But how can a CO2 laser engrave the surface of fresh fruit and vegetables?

Laser marking of food

Laser labeling of food is a special application of CO2 laser marking. In a previous article we have assessed the efficiency of laser marking on organic materials such as wood or leather. Even food can be marked without difficulty.

Broadly speaking, the process of laser marking relies on the high energy density delivered by a laser on the surface of a workpiece. It is that process that produces the desired marking on the surface.

An ordinary laser marking system is composed of three parts: a scanning head, a low power CO2 laser source and a computer equipped with the control software.

The scanning head contains three components: two galvo motors with two beryllium mirrors mounted on them; one linear actuator that dynamically adapt the focal length of a lens. The goal of this device is to deflect the laser beam and keep it always focused on the surface of the workpiece. Thanks to the laser scanning head the laser beam can be delivered on the entire surface of the workpiece.

Both the CO2 laser source and the scanning head are controlled by a software that, fed with the correct parameters, achieves the marking process of the desired design. In this way it is possible to control the speed, the position and the power of the laser beam, making it possible to obtain all types of images, logos, codes and markings.

A laser marking system can be adapted to many situations and it can be integrated in existing lines without effort.

The process of labeling trough CO2 laser marking is applicable to any sort of fruits and vegetables. Nevertheless, the best results are obtained with fruit and vegetables having a wooden or thin skin e.g. tomatoes, apples, grapefruits, walnuts, chestnuts, coconuts, pumpkins etc. In this sector it is possible to mark pieces of information such as produce traceability codes, expiration dates, logos of the producer and other personalized information.

The benefits obtained through natural branding are manifold:

• Small amount of energy consumption: the CO2 laser systems employs very small amounts of energy to do the job, resulting in a reduction of costs.
• No consumption of plastic, paper or glue: in CO2 laser labeling of food, labels are directly engraved on the surface of the product. Therefore the environmental footprint can be reduced to a minimum.
• Cleanliness: with CO2 laser marking, the products don’t come into contact with chemical substances like glue. Hence the wholesomeness of the produce is enhanced.
• Higher productivity: the laser marking process is very fast. Although the processing speed depends on the complexity of the information that must be engraved, in most situations the processing time ranges from fraction of seconds, for simple codes to a few seconds, for complex geometries.

At this stage it should be clear why laser labeling of fresh produces is also known as natural branding. It should also be clear how laser labeling is suitable for producers of organic or biological produces and, in general, for all the companies interested in improving their environmental footprint.

A case study: marking traceability codes on apples

Let’s see now how a CO2 laser labeling system has been applied to a line of selection and sorting of fresh produces, in this case apples.

This system was composed by a laser scanning head, a low power CO2 laser source with a wavelength of 10.6 micrometers and a computer with the software that controlled the entire process. The marking system was designed for the integration in the existing machine and was engineered to achieve laser marking of apples on the fly.

That means that the system was able to determine the position and the speed of each apple passing on the moving belt, thus synchronizing the behaviour of the laser beam with the position of the apples on the belt.

The system proved to be extremely fast: it could mark 6 apples per seconds. As we said this speed it’s not fixed but depends on the complexity of the results that need to be achieved.

The energy consumption of this system was of the lowest: the laser source in this applications consumed only 0,3 kW. Although it was designed for apples, this configurations of a laser labeling system can be extended to any typology of fresh fruit and vegetables and seamlessly integrated in existing production lines.

A safe process that doesn’t affect the quality of produces

Laser labeling is a safe process. The marking only affects the most superficial layer of the skin of fresh produces; all the organoleptic properties of the food are respected. They are not modified in taste, color or smell. And the shelf life remains the same: some papers have also highlighted that laser marking never reduce the quality of produces.

The laser labeling of fresh products is an application yet to be explored. The possibilities are wide and let companies greatly improve their environmental footprint.

Laser cleaning is one of laser’s many applications. The process is based on laser ablation, i.e. the removal of a portion of material from a surface. Ablation is at the basis of all common laser processes: cutting, drilling, engraving, marking.

While the purpose of these processes is to create cuts, holes or marks in the material, the aim of laser cleaning is to remove dirt particles from a given surface.

Laser cleaning of industrial moulds

The production process of thermoplastics is an example of an industrial laser cleaning application. The main production method for these materials is moulding. At the end of the production process, the moulds need to be restored to their original state. This step is crucial because the quality of the final part depends on it. The presence of material residues, or other debris, affects the final quality of the parts.

Traditionally, the cleaning process is carried out using one of three techniques: dry ice blasting, ultrasonic cleaning or manual cleaning. Each has both advantages and disadvantages.

Dry ice cleaning consists of directing a high pressure jet of dry ice onto the mould. The ice penetrates the mould cavities and removes residues. The operation is carried out by an operator who directs the jet onto the areas that need to be cleaned. The advantage of this technique is that it can be used directly in the production line. However, it is not an environmentally friendly method since it requires the use of large quantities of dry ice.

For ultrasonic cleaning, the mould is placed in special ultrasonic cleaning machines. In practice, this involves disassembling the part and immersing it in special tanks filled with solvent and water. In addition to the need to disassemble the mould, this method has the disadvantage of using polluting chemicals.

Manual cleaning consists of cleaning the moulds using a solvent and manual force. It is a slow and inefficient method.

Laser cleaning overcomes these disadvantages.

Firstly, it can be performed selectively: the laser only acts on materials that are compatible with its wavelength. Laser cleaning can therefore be used in sensitive applications where abrasion-based procedures such as sandblasting would be too invasive.

The absence of waste also makes it an environmentally friendly technique. Laser cleaning doesn’t use solvents or other chemicals, doesn’t produce any waste and also doesn’t consume water or other resources. It is a thermodynamically efficient process. The laser vaporises the material by sublimation which makes it an environmentally friendly process.

Finally, laser cleaning is extremely precise. The process is completely digitally controlled which makes it possible to work on extremely small surfaces or follow extremely complex cleaning patterns. Unlike with traditional methods, it can clean hard-to-reach spaces and uneven surfaces.

A system tailored to your application

Laser cleaning is a versatile application. It is efficient, adaptable, precise and most importantly, ecological. El.En. is the ideal partner to create a tailor-made application for your production process. Contact us and we will be happy to help you find the best solution for your needs!

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.

Corrugated cardboard, also known as corrugated fiberbord or simply cardboard, is the most widely used packaging material. Its low production cost, great mechanical properties and an overall good strength make it perfect to manufacture cardboard boxes of all kind and shape.

Generally, corrugated cardboard is manufactured by a mechanical processes. Tools such as blades, die boards or routers are used to create the profile the overall shape and to score the lines along which the folds will we made.

Mechanical processes are solid and reliable and have a long history. Yet they also have some major drawbacks:

• lack of flexibility toward changes
• limited range of admitted tolerances
• high risk of producing unwanted damage to the material
• generation of waste under the form of trimmings or dust
  

Plus, all mechanical manufacturing processes involve contact, meaning that the tools have to physically touch the surface of the material to achieve the desired transformation.

Laser technologies can overcome all those drawbacks. Laser cutters can cut shapes at high speeds and with higher degree of precision. Let’s give a general overview of the process.

Cutting cardboard with laser

The main advantages of CO2 laser fabrication derive from the fact that laser technologies are a non-contact process.

A single laser laser beam can easily engrave, cut or drill a panel of corrugated cardboard. Thanks to the properties of cardboard, the results are great. The interaction between the laser beam and the material puts in place a sublimation process: it basically means that the laser beam makes the material evaporate, achieving a precise cut.

This is a key feature of laser material processing. First of all it allows great processing speed: all things being equal, a laser cutting system is many times faster than a die-cutting machine.

A laser can achieve the same operations at a speed of thousand of meters per minute. This without compromising the quality of the cut, which always remains excellent.

Another advantage of laser material processing is its flexibility. With traditional machining process, you cannot easily change the cutting geometry.

Changing the cutting shape comes with a cost: it means changing the cutting tool. A manufacturer can hardly start a new productionrun unless it guarantees a return on the investment.

With laser material processing, changing a cutting geometry is way easier. It’s just a matter of minutes and only requires the time to load the drawing of the new geometry in the control software.

Also, a laser works like a multitool. Cutting and engraving can be accomplished with the same tool. A single laser source can perform both operations. Laser engraving is especially useful in the packaging industry, where codes of all kind need to be stamped on the packaging itself in order to comply with regulations or for logistical reasons.

This means that a CO2 laser cutting machine can conveniently process a batch of 5000 or 100.000 pieces cardboard panels of different shape.

Laser technologies can help a packaging produce meet the needs for custom products with small number of pieces. They also make possible the rapid prototyping approach for new packaging products.

A third advantage of laser technologies for cardboard manufacturing is that they don’t produce almost any waste. Laser processing is very clean: cuts and other processes are achieved without producing any scrapes, dust or other waste product, allowing for green production and better work environment.

The lack of those waste products means that the cuts obtained are of the best quality: a CO2 laser produces cuts with smooth and compact surfaces. Unlike mechanical fabrication, it does not affect the fibers of cardboard and paper: therefore the material structure remains untouched, resulting in a reduced possibilities of damaging the material.

Mechanical methods are subject to wear. The use of worn out tools reduce the quality of the product: that’s why the tools have to be periodically replaced or repaired. Those operations slow down the production process resulting, increasing the production costs. On the opposite, a laser will always be a sharp cutting tool, thus always allowing the best quality of the process.

So can you laser cut cardboard?

The answer is yes, you can. And you should. Laser technologies are the perfect tool for cutting and engraving corrugated cardboard. The laser is a fast, flexible and green tool. It allows a manufacturer to satisfy all the requests of customers: a characteristic that is essential for a company operating in the economy dominated by the paradigm of the long tail. Customers are now looking for a different approach, where the priority is given to tailor made products and respect for the environment.

A new approach requires new tools, more flexible and accurate. The tools that let manufacturers control their costs without sacrificing quality the quality are the tools of the future.

Basically, an industry based on mechanical machining was typical of an era and for a market where manufacturers marketed their products and customers were obliged to pick from what the market had to offer.

Contact us

Do you need to cut or engrave cardboard at an industrial scale and you think that laser could be a good option? Contact us: we have a long experience in designing and manufacturing a wide range of laser systems for cutting and engraving corrugated cardboard.

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.