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Introduction
This article will take an in-depth look at laser marking and engraving machinery.
You will understand more about topics such as:
What are laser marking and engraving machinery?
How laser marking and engraving machinery work
Considerations when choosing laser marking and engraving machinery
Materials used for laser marking and engraving
Laser marking and engraving techniques
Types of laser marking and engraving machinery
Advantages and disadvantages of laser marking and engraving machinery
Maintenance of laser marking and engraving machinery
And much more......
Chapter One - What are Laser Marking and Engraving Machinery? How do They Work? What to Consider When Choosing Laser Marking and Engraving Machinery
Laser marking applies readable text on a component's surface with little or no penetration. However, laser engraving is when information is applied to a part using a laser, and there is clear penetration behind the material's surface.
Permanently marking a surface with a laser involves employing a focused light beam. Different laser types, such as fiber lasers, CO2 lasers, pulsed lasers, and continuous lasers, can be used. Laser marking uses a focused light beam to label the surfaces of target components permanently. Typically, a laser machine equipped with an oscillator, a scanning mirror, and a focusing lens performs the procedure.
How They Work
Laser marking technology's focused, high-energy light beams leave permanent imprints on component surfaces. The accumulated energy is released in a coherent light beam focused on the material's surface utilizing mirrors. Heat energy is transferred from the light beam to the component surface due to the light beam's interaction with the surface. As a result, the material's characteristics and appearance will change. For example, the laser can precisely engrave, etch, anneal, or discolor surfaces depending on their energy level. In addition, the concentrated beam ensures precise, high-contrast, and high-quality marks by focusing on only particular regions of the material. As a result, the user may read or scan these permanent marks on any surface. This marking procedure is, therefore, appropriate for procedures where accuracy and permanence are paramount.
Considerations When Choosing Laser Marking and Engraving Machinery
The kind of material that needs to be tagged comes first. We like to categorize materials into two groups: organic and non-organic. Products made of organic materials include wood, glass, plastic, and paper. Anything that would ignite in a microwave, including metals, steel, and cast aluminum, is regarded as non-organic material.
What should the mark resemble once the material has been determined? Is the user seeking deep marks? Does the user want their marks to have higher contrast? Depending on the marking technology, a dark or frosted mark might be produced. For instance, one would wish to employ frosted backgrounds with dark markers if they use barcode technology and have trouble getting the vision systems to read the code. Everything depends on the specific circumstance and the desired appearance of the user's finished work.
Safety: Consider where the engraving machine is to be installed. Is there a designated, contained space for it, or will it be on the plant floor close to the operators? Will a different technology, like an inkjet, be replaced by this device? The laser provider should assist in installing a Class I laser safety system if the laser engraver is placed on an open shop floor. This process entails a laser-safe enclosure, alert lights, entryway-safe drapes, and other safety measures. A tiny laser workstation option also exists, which combines a Class I safety enclosure and laser source. If it's a Class IV laser, one would need a designated space that complies with safety regulations, including area posting, protective glasses, and a key switch.
Chapter Two - Materials and Techniques Used in Laser Marking and Engraving
Materials Used for Laser Engraving and Marking
Metal
The method can vaporize coated metals, making it appropriate for these materials. As a result, the coating is successfully removed.
Wood
Any wood can be utilized, and numerous laser cutting and engraving processes are available, making wood a popular material for engraving. Additionally, wood is process compatible. Due to the intense heat, they are frequently seen as a fire risk. The user may adjust the laser marker's strength, making it possible to engrave wood without setting it on fire. The most popular wood materials for machine engraving include plywood, MDF, and cardboard.
Marble and Granite
Granite and marble are excellent choices for picture engraving. This benefit is primarily due to the amazing contrast that granite and marble produce when they are etched. One will get a significant contrast if black marble or granite is employed, eliminating the need for additional color. If the engraving is done correctly, the final image should be white or dark gray. Finding out where the engraved object will be shown, such as whether it will be hung on a wall within a home or displayed outside, is the best approach to deciding between marble and granite. Granite or marble can be used if the piece is placed inside. However, for any items exposed to the outdoors, it is better to choose granite. This choice is so because granite is a more durable substance than marble. The Mohs scale rates the hardness of marble at a 3, whereas granite is rated at a 7 To put it into context. Since diamond has a Mohs scale rating of 10, granite is close to diamond.
Glass
All glass products can be laser engraved to create beautiful effects. Wine bottles, wine glasses, vases, and mugs are a few examples of products that can be engraved. Most reputable wineries and distilleries engrave their logos on their bottles using laser engraving. Laser glass engraving has the benefit of not significantly cutting the glass. Instead, it will leave a frosted appearance. However, the user must be careful when laser engraving glass because the laser's potential for chipping could result in a rough surface.
Fabric
Fabrics made of both natural and synthetic materials make excellent laser engraving targets. However, the most frequently laser-etched materials are cotton and microfiber. Nylon-like polyamides, polyesters, polyamide, and polyester blends are the main components of microfiber. Because of their high durability, microfibers are frequently utilized for laser engraving. A tight weave of 100% cotton can also produce stunning engraving. If the user chooses to engrave on cotton, they should use a cloth with tightly woven threads because loose threads will not produce satisfactory results. Denim, felt, twill, and fleece are additional laser engraving materials. These materials are strong enough to endure the laser's heat. The ideal strategy for engraving on cloth is low power and high speed. The top part can now be quickly burned away by the laser beam to get the desired result. Test a few samples before beginning the engraving procedure until the ideal parameters are identified. By doing this, the user will prevent their cloth from burning when they begin laser engraving it. As a general rule, steer clear of engraving any fabric with loose knittings, such as terry cloth, as they are not robust enough for the procedure.
Acrylic
Acrylic sheets, sometimes referred to as polymethyl methacrylate (PMMA), are strong and lightweight and make excellent substitutes for glass. PMMA can be produced using either a cast or an extruded process. The responses of these two varieties of acrylic to laser engraving vary. Cast PMMA's icy white appearance contrasts sharply with its clear substance. On the other hand, extruded acrylic does not provide much contrast when engraved and stays clear. Therefore, extruded acrylic is best for laser cutting tasks, while cast acrylic is best for all other laser engraving applications.
When etching cast acrylic, mirror reverse side engraving is frequently employed. The picture must be reversed to mirror the engraving on the back of the surface. There will be a stunning "look-through effect" as a result. Some engravers will also paint the sheet's surface before laser engraving it to disclose the acrylic underneath the paint. Although there are alternative ways to etch acrylic, such as using chemicals, most people use laser engravers. Since the equipment will degrade soon, laser engraving is safer and more durable than other alternatives. Additionally, the laser engraver may be programmed to produce complex designs with little effort.
Bricks and Stones
As granite does, bricks and stones work equally well for engraving items exposed to the elements. In addition, they can be used to engrave objects for exterior installations such as patios, memorials, and other outdoor structures. Laser-engraved bricks are frequently used in parks, walkways, and universities as a donation tactic. Usually, a specific pattern is pre-arranged for the etched bricks.
Historically, businesses used sandblasting to create the etched look on bricks. Sandblasting, however, is a labor-intensive and intricate procedure. As if that needed to be more, it could be more precise, and despite improvements in computer control, sandblasting frequently puts too much stress on the bricks, causing them to easily break when installed.
Laser Engraving Techniques
Laser Engraving
During this procedure, laser beams remove certain materials from component surfaces. The technique results in marks in the shape of depressions because the material melts and evaporates as it absorbs heat from the laser. Additionally, the substance will change color when exposed to air, giving the mark a more recognizable appearance. Laser engraving uses no consumables at all. Therefore, compared to other engraving techniques requiring specialized inks or drill bits, it attracts cheap operational expenses. Metals, polymers, and ceramics are just a few of the many types of materials on which a laser is effective. Engineers use it for a wide variety of applications as a result.
Laser Etching
This incredibly flexible method melts the surfaces of the workpieces to leave imprints on them. The laser beam leaves a raised mark by concentrating much energy in a condensed region. As a result, the surface will melt and expand, turning it from white to gray or black. Permanent markings like serial numbers, data matrix codes, logos, and barcodes are frequently created through etching. Additionally, it is a flexible method that works well for various metals, including stainless steel, lead, aluminum, steel, and magnesium.
Laser Ablation
Rather than removing paint from the material itself, laser ablation is frequently used to remove paint from a material's surface. Then, with no need for the ability to etch metal, the user can rapidly add a barcode or other identifier.
Rotary Laser Engraving
This technique removes material from metal components using a single or multiple-fluted cutting tool, leaving a trough where the exposed core resides. It causes a letter or item to be completely chopped off or get a deeper cut. The spindle micrometer setting determines the cut depth in the majority of applications. Therefore, most commercial and industrial workers may be employed using this method.
The most durable type of engraving, rotary engraving, can produce two- and three-dimensional appearances and can produce letters of almost any size. However, some disadvantages include the need for a larger variety of cutting tools, a rotary spindle, and a motor, as well as the fact that additional cleanup is usually necessary.
Diamond-Drag Scratch Engraving
A non-rotating tool with a diamond tip in the shape of a cone is used in this technique. The metal component receives an impression after being passed through by the engraving tool. Diamond-drag engraving is as exact and high-quality as hand engraving. The stroke's depth does not change while its width remains constant. Diamond drag is suggested for engraving jewelry and awards on soft metals.
This technique has the advantages of being generally the quickest, least expensive, and allowing for small engraved letters due to the width of the stroke. However, the fact that the stroke width is constrained is negative.
Laser Marking
Discoloration
In this method, the laser peels the workpiece's layers away to reveal the layer beneath. They vaporize to create a contrast after absorbing heat from the laser. Therefore, it is essential to ensure that the top coat's color is distinct from the base materials. Coated materials, such as anodized aluminum, will exhibit great and legible markings, making this process more effective for them. Laminated, film, and foil materials also perform well with discoloration. It works well for labeling labels, fixtures, and packaging materials.
Laser Annealing
The material surface is heated locally in laser annealing to produce the mark. The beam only penetrates 20 to 30 m of the material's surface. Hence the surface is only slightly altered—the material's color changes due to the localized heating. Depending on the heated layer, the marking could be red, yellow, green, or black. Permanent, abrasion-proof marks are produced via laser annealing. Titanium and ferrous metals are the finest candidates for laser annealing. As a result, it can be used in various industries, including those in the healthcare, automotive, food, beverage, and aerospace sectors.
Carbon Migration
In this technique, the laser's heat energy will cause plastic connections to shatter, releasing oxygen and hydrogen. As a result of this response, the mark on the target region darkens and turns gray or blue-gray. The most effective method for marking synthetic polymers and organic materials is always carbonizing or migration. It functions well with paper, wood, leather, and packaging materials. There are better options than carbon migration for dark-colored items, though. In addition, reading the markings will be challenging since the created gray mark will have less contrast than the remainder of the workpiece.
Foaming
When producing light-colored marks, carbon migration may not be very helpful; instead, foaming is more appropriate in certain situations. The laser is used to heat the material surface, which causes it to melt and release gas bubbles. The gas bubbles reflect light when they oxidize and generate foaming. One of the better marking techniques for dark-colored components is this one. This result is because the mark is lifted above the component's surface and contrasted more sharply than other surface areas. It is perfect for marking plastics as well.
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Chapter Three - Types of Laser Marking and Engraving Machinery
Fiber Laser Markers and Engravers
The fiber laser machine can be used for both marking and engraving materials. These laser markers allow users to archive different engraving depths depending on the uses of its component by varying the wattage. However, it may only function slowly on thick materials with high reflecting qualities. On most metals, it can also be unable to engrave more deeply.
For surface marking, fiber laser markers are configured to a lower wattage value of about 20 to 30 watts, and as the wattage increases, they start to engrave materials.
These solid-state lasers, whose power outputs range from 20 to 50 watts, encourage ytterbium, a rare-earth metal, to be produced. This metal element produces photons with a wavelength of roughly 1,090 nm, making them perfect for marking metals. For depth engraving or etching, use the fiber laser marking machine. They produce better results on tougher metals or when one needs a powerful system with small spot sizes to attain higher resolution. In addition, these markers are perfect for small-component batch markings due to the small spot sizes, good beam quality, and bigger lenses.
The fiber laser setup is adaptable and can label objects more quickly and efficiently. Furthermore, this laser marking technology is cheaper than CO2 lasers because it uses less power, uses less energy, and requires less maintenance. In addition, the high level of monochromatic beam filtration guarantees variable powers of one type of beam. Fiber lasers can therefore be used on a variety of surfaces.
CO2 Laser Markers and Engravers
These laser markers are frequently galvo steered sealed-tube marking systems intended to mark nonmetal surfaces. For markings like logos, date stamps, and many more, CO2 laser markers are a popular alternative. On electrical devices, integrated circuits, food and medical packaging, and electronic components, these machines assist with the creation of serial numbers, logos, and barcodes. When marking organic materials like papers, wood, and some plastic polymers, sealed-off CO2 lasers produce the best results. They work well for glass and leather markings as well.
If the output wattage is increased on CO2 laser machines, they start engraving the nonmetal materials—the more the wattage, the more the engraving intensity.
UV Laser Markers
For part marking, UV lasers are created with a 355 nm wavelength that is very absorbent. Therefore, they are ideal for "cold marking," which ensures no thermal strains on the material because of their high absorption rate. Plastics, glass, and ceramics are just a few of the surfaces that UV lasers may mark. Electronic components and medical equipment can also be micro-marked with the high-quality beam's exact marking.
Green Laser Markers
Green lasers have a power range of 5 to 10 watts and operate in the green visible light spectrum (510-570 nm). They are made to leave a mark on surfaces that reflect light well. They also have high precision and outstanding workability, which makes them perfect for delicate substrates like silicon wafers. In addition, these lasers exhibit increased material absorption and reduced heat energy. They are ideal for soft plastics, computer chips, printed circuit boards, etc. Green lasers are employed in various applications, including laser pointing devices, laser projection screens (as RGB sources), printing, interferometers, bioinstrumentation, medical scanning, and solid-state laser pumping (e.g., titanium–sapphire lasers). Due to their substantially larger absorption coefficient, such as in copper, gold, or silicon, green lasers (compared to near-infrared lasers) might be advantageous in laser material processing. By doing so, one can work with significantly less laser power and frequently achieve much higher caliber processing outcomes. As a result, the somewhat higher cost per watt is frequently justifiable. Below are the different types of green lasers:
Argon Green Lasers: Argon ion lasers are potent light sources for various wavelengths because they are based on amplification in argon plasma (produced by an electrical discharge). At 514.5 nm, green light can be produced at its greatest power. It can produce more than 20 W, but due to its poor power efficiency, tens of kilowatts of electric power are needed for multi-watt green output, and the cooling system must be of matching size. Smaller tubes for air-cooled argon lasers can produce tens of milliwatts with hundreds of watts of power. As a result, a beam of nearly diffraction-limited quality is possible.
Green Laser Diodes: Producing green laser diodes (or other green semiconductor lasers) is challenging—even more so than producing blue ones. Compared to other laser diodes, they have very short lives and a limited output of a few milliwatts. However, recent developments have been positive.
Erbium-Doped Lasers: Based on erbium-doped fibers or bulk crystals, erbium-doped upconversion lasers may emit light at about 550 nm, generally with tens of milliwatts of output power and excellent beam quality.
Helium-Neon Lasers: Although they are more commonly used as red lasers, helium-neon lasers can also be produced to emit a few milliwatts at 543.5 nm.
Copper Vapor Lasers: At 510.6 nm, copper vapor lasers have comparatively large peak powers. This quality is because they produce nanosecond pulses based on a pulsed discharge in copper vapor.
YAG Laser Markers
These laser markers have a small and light design. Their remarkable capacity to mark thin metal sheets without generating warpage or distortions explains why they are so well-liked. Manufacturers employ it due to tiny markings on various substrates like aluminum, steel, and other plated metals.
MOPA Laser Engravers
The term "Master Oscillator Power Amplifier'' (MOPA) refers to a setup that combines an optical amplifier to increase output power with a "master" laser. As an alternative, traditional fiber lasers use Q-Switch technology to generate laser beam pulses that last just a few billionths of a second. As a result, the energy from the laser is condensed into extremely powerful pulses because it is emitted in such a limited period. As a result, a MOPA laser can produce more pulses per second than its Q-Switch-powered competitors. In addition, a MOPA laser's pulse frequency range is significantly wider than found in a Q-Switch laser.
The process of annealing doesn't include any material removal. Instead, heat application results in the formation of colors while laser branding stainless steel using the annealing technique. While the capacity to create colors using a laser machine has long been possible, a MOPA laser source's advantage in precisely engraving and replicating colors is more recent.
When using a laser to engrave metals, these materials may react with their surroundings and develop rust. This trait is brought on by the amount of heat supplied to the metal's surface and the subsequent melting or burning of the edge area. MOPA lasers generate less heat, which lessens metal damage and increases a product's corrosion resistance.
Laser Coding Machines
Laser coding entails applying codes to an object using laser marking techniques, including ablation, engraving, etching, etc. The technology provides accurate permanent markings, making it superior in many ways. Laser ablation removes materials from a package surface using a laser marking device. Ablation, for instance, is the process of eliminating ink from a surface by first turning it into vapor. In laser engraving, a portion of a material's surface is removed to provide room for the inscription of codes. Every one of the high-quality laser marking techniques utilized for laser coding results in a code that is both readable and of the highest caliber.
The vector and dot matrix concepts are the two most widely used types of laser marking in the laser coding system.
Vector Marking
Vector marking results in high-quality codes. When using it, one must forgo time and energy efficiency. With the help of a focusing lens, two revolving mirrors, and other components, graphics are produced. The image is gradually created as the lens is turned on and off.
Dot Matrix Marking
This idea produces images with reduced resolution. The marking procedure is quicker as a result. By passing a laser through a rotating polygon that then directs the laser beam to a water-cooled dump, codes are generated utilizing this method.
Chapter Four - Advantages, Disadvantages, and Maintenance of Laser Markers and Engravers
Advantages of Laser Marking and Engraving Machinery
Chemicals and inks are used for marking during techniques like inkjet and chemical etching. These consumables frequently cost a lot of money and emit toxic gases into the air, which can be unhealthy. However, there are no consumables needed for laser marking. Consequently, it is a clean, effective, and eco-friendly technique. The non-contact nature of this marking method also ensures clean processing and minimizes material contamination. Compared to other printing methods, laser marking causes minimal-to-no material penetration and leaves the material undamaged.
No-contact marking is done with lasers. As a result, there is no mechanical wear between the workpiece and the laser marking system. This process guarantees that downtime and maintenance are kept to a minimum. Users also need low maintenance to clean any accumulated dust from the used mirrors.
Laser-induced marks often have excellent contrast and are permanent. In addition, these abrasion-, heat-, and acid-resistant marks are also water-resistant and fade-proof. Laser markings are, therefore, the finest option for long-lasting marking required for accurate product tracing, and one won't need to worry about the mark fading.
Laser marking uses computer and laser technology to ensure quick implementation and time savings. This technique enables users to make graphics on computers using the most recent graphic design technologies. Traditional marking techniques require specialized equipment, which adds processing time. However, laser marking devices require a command to complete the task quickly. This technology is the ideal choice for cutting the time it takes to build a product, speeding up the procedures, and saving the user a ton of money.
Each laser marking machine can mark a range of materials, and many different types of laser marking machines exist. For instance, when marking organic materials like papers, wood, and various plastic polymers, CO2 lasers produce the finest results. Similar to how Nd: YAG and fiber lasers may work with various metal grades, including steel, stainless steel, aluminum alloys, etc. Plastic, glass, and ceramic surfaces can all be marked using UV lasers.
Laser markers can successfully label a larger product batch with a particular design within a mass manufacturing system. It is simple to incorporate similar markings into a production line using this marking technique. Additionally, the repeatability is reliable, enabling quicker turnaround times and attractive goods.
Disadvantages of Laser Marking and Engraving Equipment
A skilled user must use a laser engraver to its fullest capacity and produce markings of the highest caliber. As a result, operational costs rise due to the increased demand for knowledge. Furthermore, the quality of the markings is determined by competence.
Comparatively speaking to other marking system machines, engraving machines are more expensive. They also cost a lot to operate and maintain. This investment demonstrates that employing one will involve both an initial and ongoing commitment. Outsourcing to a laser engraving service is advised due to the high operation and maintenance costs.
When marking, the devices release harmful chemicals and vapors. As a result, for a secure working environment, the user needs efficient ventilation and a protective system.
Maintenance of Laser Marking and Engraving Machines
Cleaning Lenses and Mirrors: Cleaning the optics (mirrors and lenses) once a week is one of the greatest ways to maintain a laser engraver's functioning at its highest level. The mirrors and lens can become clogged with smoke, glue, and other pollutants, which not only lowers the laser's output but also has the potential to harm its optics. It merely takes a high-quality cotton swab soaked with optics cleaner to clean the optics. A single assembly that includes the lens and mirror can be taken out and cleaned separately from the machine. Gently dab the optic after wetting the swab with cleanser. Rotate the swab after each dab to reveal clean cotton on the surface until the optic is clear of any visible pollution. After using the swab, obtain a new one to complete cleaning, and be careful not to brush anything too hard because doing so could harm the optics. Allow the optics to dry after cleaning is finished before using the engraving machine.
Clean the Crumb Tray: The crumb tray is a component of the laser engraver used to catch any small particles that may fall through the machine's vector cutting table while it is in use. The crumb tray, which sits beneath the vector table, needs to be maintained tidy, and the trash that falls through the table needs to be taken out frequently. Open the laser's front access door, slide the crumb tray out of the front, and then throw away all the debris to clean it. The accumulation of soot and debris in the crumb tray could eventually pose a fire risk if it is not maintained clean.
Vent Maintenance: The vents of laser engravers collect dust and other contaminants with time, just like any machine used regularly, and must be cleaned for the engraver to function correctly. Use a flexible plastic or wire brush that may fit into the vent to clean the engraver's vent. A similar technique will also need to clean the downdraft ports.
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