Laser drilling consists of creating micro-holes on various types of materials. It is one of the first applications of laser for material processing.

The technique is based on the sublimation process by a focused laser beam. The laser concentrates the energy on the surface of the material, making it pass instantly from a solid state to a gaseous state. In fact, the material is vaporized and what remains is a perforation of the desired measurements.

Types of laser perforation

There are different types of laser drilling. Some are cleaner or more efficient than others.

single-pulse drilling: a single pulse creates the hole. This technique makes it possible to make holes smaller than a millimeter on materials up to 1 mm thick

double-pulse drilling: works like the previous one, but in this case the hole is created by two pulses in rapid succession

percussion drilling: the hole is created by sending multiple laser pulses on a single point

trepanning: the laser beam follows the perimeter of the hole to be made. This type of processing allows for larger holes – smaller than 3 millimeters – to be made on materials less than 3 millimeters thick

helicoidal drilling: the laser moves in a spiral starting from the center of the hole and progressively removes material as it travels. This technique allows you to create small holes on materials as thick as 25mm

The type of application and processing will depend on the intended result and type of material used.

Laser drilling advantages

The drilling of materials with traditional methods, is a slow and delicate process. When carried out mechanically the risks range from breaking the material (in cases of fragile materials such as ceramics) to the impossibility of precisely controlling the characteristics and distribution of the holes.

Yet, laser drilling is a non-contact method and therefore many of the typical disadvantages of traditional processes can be overcome.

The advantages of laser drilling are numerous:

• It creates very quickly a great number of holes
• It drills any material (however hard) capable of absorbing the laser radiation
• parameters such as shape and size of the holes can be tightly defined
• the material can be pierced at almost any angle
• the processing speed is very high
• the hole tapers can be controlled in a very precise way
• the density of the holes on the surface can be definined precisely
• processing waste are eliminated

In which sectors is laser drilling used?

Laser drilling is used in a wide variety of sectors. The ability to control the shape, size and number of holes per unit area has made it very popular. Here are some examples.

As a first example of application, we can cite is the manufacturing of acoustic panels. By varying the laser parameters it is possible to make sound-absorbing panels perfectly calibrated to the frequency that needs to be absorbed. With the same processing it is thus possible to create panels for every application, from the automotive sector (panels that absorb engine noises) to architecture and decoration (panels to optimize the acoustics of concert halls and other public spaces).

Another very useful application is the manufacturing of micro-drilled plastic bags for produce packaged in a modified atmosphere. If properly made, the holes make it possible to optimize the gas exchange between the inside and the outside of the packaging and therefore considerably extend the shelf-life of these products.

Which materials can be subjected to laser drilling

Laser drilling can be performed on a great number of materials. CO₂ laser, which works with both metals and non-metals, is particularly versatile. Here is a list of materials that can be laser drilled:

• paper
• cardboard
• acrylic plastic
• plastic film
• wood and plywood (mdf)
• ceramic

Examples of laser drilling

Which sources are suitable for laser drilling

CO₂ laser sources are best suited for laser drilling on non-metallic materials and on some types of metals. Their wavelength makes them very versatile and flexible for a large number of applications.

If you are considering to start a production based on a laser drilling process, you can contact us. Our expert will be happy to give all the information you need to find a laser material processing solution.

Laser kiss cutting (or kiss die cut) consists in removing the superficial portion of a sheet of material according to a specific cutting path.

Unlike normal laser cutting, laser kiss cutting does not go through all the material but remains on the surface layer.

Due to this characteristic, kiss cutting is mainly used in the paper converting and textile industries.

Laser kiss cutting is used when the superficial layer of a material made up of two attached sheets must be cut.

Laser die cutting of labels is an example of one of the most common applications of kiss cutting. The laser cuts out the surface layer into the shape of the adhesive to facilitate its removal from the support layer.

Laser kiss cutting can also be applied to the field of fabric decoration.

Kiss cutting for digital converting

Digital converting or laser converting is used to perform paper converting processes that would be difficult or impossible to achieve with conventional mechanical methods.

Laser kiss cutting is a typical digital converting application that, as previously mentioned, is particularly used in the production of adhesive labels.

This technique makes production particularly efficient and advantageous, since the costs and time required to set up the machine are eliminated.

In this sector, the materials most used for kiss cutting are:

• paper and derivatives
• polyester
• plastic film
• adhesive tape

Kiss cutting for the textile sector

In the textile industry, laser kiss cutting and laser cutting are used to decorate both semi-finished fabrics and finished garments. In the latter case, laser kiss cutting is very useful for creating personalized decorations.

This technique makes it possible to create different effects such as embroideries, appliqués and labels of various types.

Generally speaking, in this family of applications, two pieces of fabric are sewn together.

Laser kiss cutting then cuts out a shape on the surface layer of the fabric. The upper shape is then removed making the underlying drawing visible.

Kiss cutting is applied mainly on the following textile materials:

• synthetic fabrics in general, in particular polyester and polyethylene
• natural fabrics, especially cotton

The advantages of laser kiss cutting

The kiss cutting technique is not a modern discovery related to laser technology but dates back to traditional printing techniques.

Compared to these mechanical cutting methods based on blades and dies, laser kiss cutting offers several advantages:

• the cutting path can be very complex, making detailed and precise cuts
• the possibilities for customization are innumerable even within the same production cycle
• it can be performed on a large number of materials without interrupting production
• cutting tools don’t get worn during production which therefore eliminates the need for maintenance
• speed, productivity and processing quality are at their maximum
• edges are clean cut and defined and do not need further finishing

The industries of laser kiss cutting

As we have seen, laser kiss cutting is mainly used in the digital converting and textile decoration sectors.

Examples of laser kiss cutting

Which laser systems are suitable for laser kiss cutting

Each laser kiss cutting application must be tailor made for each customer’s needs. In the label industry, a system consisting of a CO₂ laser source and a scanning head is generally used.

The laser source

For the manufacturing of labels, high power isn’t necessary: most applications can be done with a laser source below 500W.

Keep in mind though that the power is directly proportional to the production speed. It is therefore sometimes necessary to resort to higher power because of production needs.

A small clarification on the source’s wavelength: El.En. has developed a CO₂ laser source specially designed for label manufacturing, the RF333P, with a wavelength of 10.2 micrometers.

This wavelength is ideal for polypropylene (PP), of which is made the surface layer of most labels is made. This source is a variant of the Self Refilling series, which are the most suitable for paper labels.

The scanning heads

The scanning head always works in combination with a laser source. Its function is to move the laser beam on the work surface and keep it focused. To do this work the source uses mirrors mounted on galvo motors and a focusing lens on the Z axis.

El.En. produced a scanning head for CO₂ lasers called GioScan. The machine is available in two models:

• GioScan 1735, capable of operating on a surface between 135×135 mm and 800×800 mm
• GioScan 1770HR, capable of operating on a maximum area of ​​2300×2300 mm

A laser system for each laser application

Laser kiss cutting applications are numerous and ultimately depend on the material and production needs.

The advantage of laser technology is that it is possible to create custom applications.

For over 35 years El.En. has produced laser systems for industrial applications.

If you have a production idea in mind that requires laser kiss cutting,

Cardboard and CO2 laser

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.

Governments and organizations are constantly seeking solutions to make identification documents secure and tamper-proof. Cost-effective productions are key because in most cases security requirements combine with the need to maintain low costs.

Until not so long ago, all identification documents were made of cheap and readily available materials such as paper or cardboard. The document’s information was printed in ink or handwritten. Of course, not just any paper was used. In order to guarantee the originality of the document and combat counterfeiting, the paper was made using special treatments. Holograms, watermarks, or drawings were applied to the paper to make it as difficult as possible to falsify.

However, these products were not 100% safe since they could still at times be forged. Both the types of paper and the inks could be modified in such a way as to deceive even the most expert eye. This is the reason why the search for forgery-proof solutions has never ceased.

One of the solutions found was the laser marking of documents. The application consists of marking information directly on the material using the laser beam. The interaction between the laser and the material changes the surface layer causing a transformation that produces a mark. This mark is therefore not applied to the material but is an integral part of it. This technique guarantees that any successive modification to the document would result in irreparable damage that would highlight the counterfeit.

Laser marking can be used both on security paper – and on paper in general – but also on new-generation plastic identity documents.

Various objects such as ID cards, passports, credit cards, passes, or even hospital wristbands can be made using laser marking.

Given their identification function, these documents must have very precise functional characteristics:

• the sign must be indelible and resistant to wear and tear.
• the document must be difficult to forge or tamper with.
• there can’t be any defects
• all documents must be identical

The marking process makes it possible to meet all these requirements and therefore satisfy the most stringent international safety requirements. The marking becomes an integral part of the material and cannot be removed. It is virtually impossible to forge a laser marked document unless you use the same tools and materials as the original document.

The laser marking process, like all laser processes, is computer controlled and therefore has a high repeatability and accuracy index. Once the process has been defined, the possibility of error is 0, and machining operations are carried out repeatedly with the same level of quality.

Laser marking lends itself to numerous applications. You can mark alphanumeric identification codes but also barcodes, QR codes, and even greyscale photos.

Laser allows you to add special security features such as microtext, variable images, i.e. images that change depending on the angle.

How the marking process works

It is a well-known fact that laser marking can be performed on various types of material. The best result is obtained on plastic materials such as polycarbonate and paper.

The marking on plastics is done by chemical degradation. The energy transferred by the laser carries out instantaneous transformations at the molecular level. The transformations change the visual appearance of the material by creating a dark-colored mark.

Laser marking also works on multi-layered documents. The laser can even reach a transparent layer by setting a specific wavelength. Marking can, therefore, be done at deeper levels and ensure that the mark is protected by a transparent surface layer and thus more resistant.

The possibilities go even further. Deeper marking with a tactile effect can be created through laser engraving techniques.

Laser engraving acts at a deeper level than laser marking and subjects the material to wider and more radical transformations. The mark made by engraving doesn’t only have visual characteristics but also tactile ones. The combination of marking and engraving makes the ID much safer.

The laser marking process allows for results that cannot be obtained with other machining tools. Therefore it lends itself to the most advanced processes. In a world increasingly connected, having forgery-proof documents is more and more necessary. If you have such an application in mind contact us , we will help you make it happen.

Laser engraving and marking for fabric are some of the innovative technologies that have taken hold in the fashion and interior design sector. Indeed, their introduction has given a sector that usually relies on unchanging production processes, the impetus to experiment.

Laser marking and engraving processes are fast, accurate and flexible. These characteristics make them perfectly compatible with production processes and explain why their use has spread so widely.

The introduction of laser has made it possible to significantly reduce the environmental impact of this industrial of the fashion industry, which is one of the most polluting. The production cycle of fabrics, from production to finishing, involves the consumption of considerable quantities of water, energy and chemicals.

Laser technology has therefore also established itself as an alternative production tool, capable of replacing all traditional processes with lower costs for the company and above all for the environment and with greater benefits for the end user.

Marking or engraving? The difference between the two processes

In the textile sector, lasers are used throughout the production chain, from cutting to finishing and decorating fabrics. The marking and engraving applications are mainly used in those parts of the production process.

Both applications use the laser as an energy source to remove a layer of material of varying thickness. Depending on the amount of energy transferred by the laser to the material, the layer of material removed is more or less deep and the transformations made to the material are different. The difference between marking and laser engraving lies precisely in these differences.

We speak of laser marking when the processing involves the material’s most superficial layer and its transformation is not radical. Oppositely, we talk about laser engraving, when the laser beam removes a consistent layer of material. The engraved mark is deeper and perceptible to the touch.

Given these differences, laser marking and engraving results can differ according to the chosen type of application or material.

Based on all the aforementioned information, laser marking and engraving can suit numerous applications. Laser is a very flexible tool that adapts to all types of applications.

In general, we can say that laser marking and engraving applications on fabric fall into one of these two areas: the decoration or the application of various types of information on the material’s surface.

Laser marking and engraving for fabric decoration

Laser decorations allow designers to fully express their creativity. They can create a wide range of decorative effects and details on fabrics by using marking or laser engraving. These can range from a simple geometric pattern to the transposition of images in grayscale, all the way to the creation of decorative details with a three-dimensional effect.

The decoration of denim fabric is a perfect example of how this field of application has become popular in the clothing industry. The laser marking of demin has revolutionized the way this fabric is processed. Traditionally the denim finishing process involved various steps such as washes, sandblasting and abrasion. These processes were used to give a particular look to the jeans, a specific shade or a worn look to the garment through cuts and abrasions. The problem with these processes is that they are extremely polluting, involve a large consumption of resources and have a significant negative environmental impact.

Denim laser finishing makes it possible to significantly save on product manufacturing times, optimize the production process, perfectly replicate the various types of denim washes, and create any detail with great flexibility. All these results can be obtained through the laser’s transfer of energy on the material’s surface rather than through the previously mentioned consumption of resources.

Laser marking and engraving to communicate information

In a world where automation is becoming increasingly popular, the application of information on materials is an increasingly requested process. Laser marking and engraving can be used to apply barcodes, alphanumeric information, information on the characteristics of the product and its maintenance.

This information can serve different purposes. For example, imagine a manufacturer of fabrics destined for the semi-finished product market. By means of laser marking, he can automatically imprint information such as production batches and identification codes directly on the fabric.

The advantage of this type of application is that the information engraved or marked with the laser is indelible, resistant to wear and counterfeiting. The manufacturer can save on some production costs, and when it comes to logistics and traceability, have a fully automated production process. The product buyer also has the guarantee that important information applied to the fabric won’t be damaged by time or wear.

Fabrics that can be laser marked / engraved

All categories of fabrics can be laser marked or engraved. However, some of them are better suited to these processes. Below is a brief review of the fabrics on which laser application can be performed very easily:

• Synthetic fabrics. Synthetic fabrics are among those that are best suited to laser marking / engraving processes. These are materials made from thermoplastic polymer fibers, such as polyester. These materials respond very well to laser processing and therefore give optimal results.
• Natural fabrics.Cotton is the natural fiber that is best suited to laser marking / engraving processes. To mark cotton you need to choose fabrics with a fairly compact texture.
• Leather and faux leather . Laser marking can be applied to both natural and synthetic leather. Not only can laser technology be used to perform traditional processes, it can also create effects that could not be obtained with traditional tools.

How a laser system for marking fabrics is made

The components of a fabric laser marking / engraving system depend on the type of application needed. However, some basic components needed for typical engraving and marking applications are always necessary: a laser source and a scanning head.

The laser source is the device that generates the beam that performs the process. Their versatility when it comes to different materials makes CO2 sources the most suitable for these types of processing. Deciding how powerful the laser source should be is directly proportional to the manufacturing speed required. The more powerful the laser source is, the more instantaneous the execution.

The scanning head and attached software system can make any type of pattern in a very short time. They are therefore perfect for this type of processing, even if performed at high speeds.

An application with infinite possibilities

The laser marking and engraving of fabrics will increasingly take center stage in the fashion industry. The advantages they offer in terms of flexibility, accuracy and speed are enormous. Moreover, their greatest advantage for an industrial sector that makes innovation and design its essential strength is their endless application options.

Are you in need of a laser engraving or marking application? Contact us and we will happily put our extensive experience at your service to devise the ideal solution for your needs.

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

Polypropylene: characteristics and uses

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

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

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

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

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

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

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

Can you cut polypropylene with laser?

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

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

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

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

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

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

Implementing a laser system for polypropylene cutting

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

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

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

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

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

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

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

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

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

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

The interaction between PTFE and CO2 laser

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

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

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

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

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

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

Laser cutting Teflon

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

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

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

PTFE Laser drilling

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

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

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

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

PTFE Laser marking and engraving

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

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

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

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

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

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

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

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

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

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

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

Traditional wire stripping methods and their drawbacks

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

This method has many drawbacks:

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

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

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

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

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

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

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

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

Why laser stripping works

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

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

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

The advantages of laser stripping

Laser stripping offers several advantages over traditional methods:

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

What are the different types of laser stripping

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

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

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

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

How a laser stripping system is made

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

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

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

Implement your own laser wire stripping

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

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

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

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

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

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

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

Laser technology for abrasive materia die cutting

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

Laser’s main advantages in cutting abrasives are:

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

A very promising sector

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