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.

Laser material processing started a revolution in the industrial world. It has brought quantitative improvements such as an increase in production speed, and qualitative ones, such as the possibility of creating customized products with high added value, even on a small scale.

The packaging sector immediately understood that the use of laser could offer endless possibilities for innovation. Packaging is a fundamental aspect of most manufacturing sectors and laser technology is taking a strong foothold in this growing market. Laser reinforces and improves the characteristics of packaging materials, helping them perform their desired function even better.

Packaging in itself performs a wide range of functions:

• First of all, it has a protective function. Packaging must protect the product from external agents. In the case of food, it prevents deterioration and guarantees the product’s integrity
• Secondly, it has an aesthetic function. Packaging must convince the consumer to choose a specific product on a supermarket shelf. In a world increasingly rich in consumer goods, packaging can sometimes be a product’s only distinctive factor
• Thirdly, it has an informative function. Important informations such as ingredients, expiry date, production lot or barcode must be visible on the product
• Last, but not least, it has a practical function. Packaging must make the product easy to handle and use. Thanks to laser cutting, packaging can be designed in such a way as to facilitate the use of the product itself. Easy to open packaging such as food bags or easy cutting ones such as yoghurt pots are two examples of this type of packaging.

Functional and fast packaging with innovative technology is now easier than ever with laser technology.

Why process packaging with laser?

Laser-based manufacturing is extremely flexible and give the possibility to experiment on a great variety of applications. Laser, and in particular CO2 laser, achieves its maximum levels of efficiency when it processes the most commonly used packaging materials such as:

• paper and cardboard: used to produce boxes and packaging, these materials can be cut, marked and perforated. The producers can thus create boxes with original shapes that can bring out the abstract qualities of the product
• wood and derivatives (for example MDF) are used to create innovative packaging. Food crates to transport produce are but one example
• plastics and derivative: thermoplastic film polymers such as polypropylene, polyethylene and PET are among the most used materials for packaging. Plastic film can be adapted to the most diverse needs through cutting, marking or drilling processes. Food safe plastics benefit greatly from these applications. For example, containers can be perforated, to regulate the passage of air or to create filtering systems, but also be cut into complex shapes. Other applications in this sector include the cutting of plastic films used to make various types of packaging, including aluminised plastic films

Laser technology is also a great asset for the packaging sector because of the possibilities offered by automation. The benefits of a fully digitized and automated manufacturing process are significant. The automated process reduces the possibility of errors, allows changes to easily be made in real time, guarantees extremely uniform results while having standard and repeatable characteristics.

For example, imagine being a manufacturer of plastic parts for the automotive industry. A digital manufacturing workflow would allow you to automatically use laser to engrave a production batch number on a piece’s packaging, centralize this information in a database, as well as have a system that allows you to trace all the logistics, from the production to the end customer. Should there be a defect or a malfunctioning piece, the production batch (or any other information) could easily be looked up directly in the database.

Laser processing in the packaging sector

Many of the advantages derived from laser processing are due to the fact that laser is a no-contact technology. The laser beam is used as an energy source that gets concentrated on a specific area in order to perform an application. Here are some of the main applications laser systems can perform.

Laser cut

In laser cutting, the beam vaporizes a portion of material according to a defined path. The final quality of the cut depends on the material. CO2 laser cut creates extremely clean edges on most materials. The final piece does not need further finishing and is ready for use.

Laser cutting can be used to cut windows and openings on a package, to create details such as tear openings, easy-to-open tabs, filtering systems, to cut pieces of packages for later assembly.

Laser marking and engraving

Laser marking and engraving use laser to imprint a mark on a material. The two processes are very similar.

We speak of laser marking when the transformation of the material occurs only superficially. In the case of laser engraving, there is a deeper transformation of the material.

In the first case the sign, even if indelible, results in a discoloration of the material. In the second case the sign is much deeper and it is also possible to obtain a tactile sensation on the incision.

Manufacturers mostly use laser marking and engraving on packaging. Laser allows them to permanently engrave their logo in remarkable detail. Expiration dates or production batches can be applied on the packaging, taking advantage of the automation capabilities offered by laser systems. This application is known as laser coding.

Perforation and laser microperforation

Drilling machines use laser to create holes on a material. Typically the holes are made on sheets or slabs of material. Finished pieces can also be perforated.

The holes can have different dimensions. Indeed, the possibility of varying the size of the perforations in order to adapt them to a specific purpose, is the true advantage of laser perforation.

The term laser microperforation is used when the holes have microscopic dimensions. Laser perforation and microperforation have numerous applications in the packaging sector.

Laser perforation can be used to create filters and other features on the packaging, such as the creation of perspiration holes for food trays.

Laser microperforation can be used to create breathable packaging (such as modified atmosphere packaging). In this case, microperforation can be used to calibrate the packaging to the product and increase its shelf life. The processing of flexible plastic films takes great advantage of this application which allows you to create wraps capable of significantly extending the life of the product.

A sector in constant evolution

Laser technology makes it is possible to decide on a desired result and calibrate the process on it. Many laser applications have not yet been tested which means there is a whole world of opportunities to explore. The tailor made application that could bring numerous advantages to your production system could be just around the corner.

Here at El.En., we have experimented with thousands of laser applications for packaging over more than 35 years. If you work in this sector and are looking for your next personalized application, contact us and let us know what you need. We will be happy to help you build the ideal solution for your application!

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

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

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

The advantages of laser microperforation

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

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

What materials can be processed with laser microperforation?

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

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

Which laser source to choose to execute laser microperforation?

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

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

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

Laser marking has become a standard in many industrial sectors. Its advantages are flexibility, speed, precision, the quality of the etched signs, eco-friendliness.

The vast majority of laser marking applications are aimed at identifying products and components. This role is traditionally played by labels of various types, printed or engraved and subsequently applied to products. Laser marking replaces the labels and allows information to be engraved directly on the surface of the product or component.

How laser marking process works

The laser marking process takes place through the interaction between the laser beam and the surface of a material. This interaction triggers an ablation process, through which a superficial layer of variable size is removed. The final result depends on which type of material is being marked and which type of laser is being used. The CO2 laser is the most used in laser marking processes because it can be applied to many materials.

What information can be laser marked

Laser technology makes it possible to engrave all kinds of information about a product. Some examples are:

• barcodes
• QR codes
• sequences of alphanumeric characters
• production lots and expiration dates
• copyright information
• manufacturer’s logos
• compliance logos

The advantages of laser labeling

Currently, there are three main ways to apply information on the surface of a product:

• Inkjet printing. It prints alphanumeric codes using a dot-matrix printer. This type of application is used on organic products that could be damaged by the laser’s heat. However in recent years it has been found out that laser can also be used successfully to label fruit, vegetables and other organic materials. Even if ink-jet printing guarantees a high level of productivity, it isn’t always long lasting since different materials retain the ink better than others, and the maintenance of the production line can be costly.
• Metal stamping. It prints signs by plastic deformation of the material’s surface. The imprinted marks are evident and can’t be counterfeited easily. It can be applied on metal labels that are then affixed to the different components, but it is not suitable for direct marking applications on the component itself. Metal stamping requires the use of a specific imprinting tools and dies, which have high maintenance costs. Also, changing the information to print is expensive because it requires changing the printing tool.
• Self-adhesive labels. Information is printed on a self-adhesive label which is then applied to the product. Labels are not very environmentally friendly because the back of the stickers are discarded.

Compared to these marking systems, the creation of labels by laser marking has undoubted advantages.

• Quality. Laser markings are perfectly defined and never fade, however much the product is subjected to intensive use. Laser technology suits well where preventing counterfeiting is necessary.
• Cost. While it is true that laser requires a greater initial investment than the other methods, it also has much lower maintenance and processing costs. Laser is advantageous when used in production processes that foster its strengths, that is favor high levels of customization, highly automated management of processes and perfection of the output.
• Flexibility. The printed information can be modified and updated very quickly without the need to adapt work tools or its ensuing costs. Tooling changes and machine preparation are reduced to practically nothing. Laser marking makes it possible to access a piece’s recessed areas that would remain inaccessible with conventional technologies.
• Respect for the environment. Laser labeling is more eco-friendly than traditional labeling since the consumption of plastic, ink and glue for labels is reduced considerably, as well as the costs associated with the disposal of unused sticker’s support.
• Efficiency. The information on the labels can be immediately digitally processed. It is therefore possible to increase the traceability of the processed pieces. Laser marking of labels can also be made on the fly.

Applications

There are many laser marking applications which range from the traditional ones like the marking of parts and components to the more advanced ones like the laser marking of food. There are many examples of applications in this latter area:

• engraving of codes on eggshells: this case study shows how laser marking can replace ink printing on eggshells
• marking of cold cuts and cheese wheel: cheese wheels and cured meat can be easily marked with laser. In this application laser marking replaces hot marking
• marking of fresh produce: in this application, laser marking is used to engrave information and logos directly on the surface of fruit and vegetables. In this case, laser marking replaces the self-adhesive labels

Other application examples include:

• Automotive: windshield engraving, identification of car components
• Gifts: product information
• Electronics: laser marking marking of silicon boards for integrated circuits
• Engineering: marking of construction components

What is your application?

You might be considering how laser marking could help you improve your business. Here at El.En., our team of experts will be happy to help you choose the right laser system for your needs. Our laser sources and our scanning systems are used all over the world and help thousands of companies create high quality products. Contact us to learn more.

Paint stripping operations have always been an expensive and time consuming process. Removing paint from an object, especially a large painted surface, requires many hours of work. In most cases, solvents and big quantities of water are used to strip paint which has negative consequences on the health of workers and the environment.

An alternative to traditional paint stripping is laser paint removal, an effective, fast and environmentally friendly method to remove paint from a surface.

Traditional paint removal methods

Paint has been used to cover surfaces and object since ancient times. Their function is twofold: on one hand they protect the material they cover from wear and tear, on the other, they strongly contribute to the aesthetics of the object.

Practically all industrial sectors make use of paint, but for some, it is a crucial part of the production process.

This is the case, for example, in the vehicle manufacturing industry, whose objects – airplanes, ships or trains – have large painted surfaces.

Aircraft can be repainted in cases of general maintenance or after a change of ownership.

Traditionally, chemical and physical methods are used to remove paint, i.e. the paint is softened with solvents and then scrapped mechanically. This technique has other drawbacks:

• it uses of highly polluting substances
• areas that don’t need stripping need to be masked to avoid damage
• the chemicals used need to be rinsed off, which causes a high water consumption
• it produces potentially toxic waste and chemical vapors which are bad for operators and the environment

Laser depainting makes it possible to overcome these drawbacks, transforming stripping into a fast, effective and precise process.

The process of stripping paint with laser

The laser paint stripping process consists in irradiating the painted surface with a laser beam that vaporizes the paint layer.

The paint is removed practically instantly thanks to a sublimation process. Compared to traditional methods, laser paint stripping is a much faster process. In a few hours it is possible to remove tens of square meters of paint from a surface. The only consumption of resources is the electricity used to power the system.

Harmful solvents or other chemicals are unnecessary. Just apply the laser to the surface and in a few seconds, the paint is removed.

Which technology for laser paint stripping?

Defining the technology suitable for a laser stripping system in detail is difficult without knowing its specific context of use. The fundamental components of a system of this type are a laser source and scanning head.

Theoretically, the choice of the laser source depends on the chemical composition of the paint to be removed. It is a well known fact that each material absorbs a certain wavelength more or less well. The most efficient laser source has a wavelength that is best absorbed by the material it is trying to sublimate.

However, an important consideration must be made. It would not be viable to create a paint stripping machine which could only strip on one type of paint. A laser depainting machine must be able to remove the greatest number of paints on the market.

The CO2 laser offers the best compromise between reliability and versatility. A carbon dioxide laser source is therefore the most suitable tool for this application. The wavelength of 10.6 micrometers is in fact effective on most of the paints on the market because it is highly absorbable. It can remove both white and colored paints, without damaging the underlying surface.

The scanning head is the other fundamental element of a system for laser stripping. This device is used to precisely direct the laser to a specific part of the surface and to keep it focused on that work area. These two characteristics make it an extremely precise work tool.

The choice of the head depends not only on the laser used, but also on how much surface needs to be covered. Large surfaces require particular scanning heads such as the El.En. AZSCAN HR70 which manages to cover an area as big as 2300 x 2300 mm.

The fundamental components of a laser system for paint stripping are The laser source and the scanning head. However, their implementation is strongly guided by the type of work needed. The possibilities are endless and each application requires the study of a tailor-made system. Contacting our technicians is the best way to find out the possibilities this application offers.

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

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

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

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

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

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

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

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

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

Examples of thermosetting polymers are:

• polyimide
• polyurethane
• bakelite

The main thermoplastic polymers are:

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

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

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

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

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

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

How to choose the right laser system for plastic

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

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

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