Previously, when manufacturers had to mark a surface with a pattern such as a barcode, image or text, they had to choose between traditional engraving or screen printing. These processes, though, were costly, nonpermanent and often damaged parts.
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With the implementation of laser marking, though, engineers are able to create characters, numbers or images without compromising the parts. Instead of using a physical tool to etch the surface or transmit ink, this process uses focused laser light to produce damage-free, easy-to-read marks.
Laser marking has become an essential part of the manufacturing industry ' helping businesses keep track of their products, improve quality, minimize counterfeiting and more. To help understand the potential behind this technology, we've laid out the benefits of laser marking in manufacturing.
Other marking processes, such as inkjet or chemical etching, use inks and chemicals in their marking ' which not only are expensive consumables for the business, but have a negative effect on the environment. Laser marking, on the other hand, does not use any consumables ' making is clean, affordable and energy efficient.
It also eliminates costs and downtime associated with cleaning, fixing or powering printers. While labels can peel off or become damaged over time, laser marking, provides permanent identification for parts and does not have to be performed multiple times.
Because the process is non-contact, laser marking ensures clean processing with minimal contamination. Where printing systems will burn down the material by marking, the damage-free process involves minimal or no material penetration.
Many federal groups require some sort of identification to comply with laws that uphold quality, traceability and other safety standards. Automotive companies, for example, use part traceability to quickly determine when and where a part was produced in the case of a component failure ' aiding in recalls.
When it comes to the medical industry, the Food and Drug Administration requires all medical manufacturers to include a unique device identifier on devices labels and packages. This UDI is a unique code that consists of a device identifier, which identifies the labeler and the model/version, and a production identifier, which represents several parts such as expiration date, serial number and other codes.
Similarly, the Federal Aviation Administration requires aerospace engineers to include certain marking in propellers, engines and other parts. It's up to the FAA to determine which markings are required on each part (such as model, builder and certification), but they must be marked with an approved fireproof method.
Another one of the benefits of laser marking is the ability to connect with the IIoT. Previously, large manufacturers with multiple laser marking machines would have to manually upload a new job each time there was a new order (which was a time-consuming and inefficient process). Mecco Marking and Traceability developed a system to meet the needs of smart manufacturers by streamlining this process ' connecting automation and laser marking to the IIoT.
Mecco created a programmable logic controller that works as a smart board, allowing one factory manager to managing multiple jobs or automation lines simultaneously and remotely.
'Historically, marking systems have not been able to communicate directly with a PLC,' David Sweet, president of Mecco Marking & Traceability, explains. 'It's been a challenge for manufacturers who want to incorporate automated part marking into their processes. The Remote API'and its ability for bi-directional communication'is a key benefit for us. It has allowed us to do what we couldn't do before: seamlessly connect our clients' PLCs with their laser marking devices.'
Counterfeiting has a huge impact on the global pharmaceutical industry ' an epidemic that is not only illegal, but has many social and economic implications. It's estimated that 10 percent of global pharmaceutical sales are counterfeit products. Not only has this cost the industry $16 billion, but it opens up a bridge for organized crime and terrorism.
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Pharmaceutical manufacturers are limited in what type of marking they can use. The marking must be tamper-proof and easy to read, compatible with the environment and cannot alter the product. Because of this, the most viable solution is laser internal engraving ' a similar process that leaves a laser mark you can both see and feel.
'The recent development of industrial-class ultrafast lasers enable internal marking without any damage to the container,' Eric Mottay of LIA Today says. 'Because of the extremely high optical intensity and very short pulse duration delivered by ultrafast lasers, there is no heat dissipation during the interaction process, which means that there is no micro-crack formation. Therefore, since the individual spots can be made very small, it is also possible to achieve virtually invisible marking, and yet to guarantee reliable reading under proper lighting.'
With laser marking, there is no need to etch a product or transmit ink onto the surface. Instead, laser light is focused onto a material to produce damage-free marks.
Here at Apple Rubber, we use Apple LaserMark, a Samurai UV Laser Marking System, to mark our parts. One benefit of this tool is its beam quality, which leads to a smaller spot size of the laser. The small spot size, along with short pulses, produces high peak power which is beneficial in deep marking with crisp, clear marks and small characters.
What benefits of laser marking in manufacturing have you found? What have you learned about the future of this technology? Let us know by tweeting us at @AppleRubber.
Laser marking can be a quicker and more efficient marking process than chemical etching and inkjet printing. Chemical etching requires many steps that can last days, and laser marking happens instantaneously. Inkjet printing/labeling has consumables and replacement parts that can slow down the process and often lead to downtime'laser marking technology does not.
There are a myriad of reasons why businesses are moving towards using fewer consumables. Here are a few of them:
Whatever the reason may be, laser marking technologies are often a viable solution. Laser marking machines use light to directly mark products and do not need any other materials. Because of this, there is no extra maintenance, material, PPE, or toxic waste costs.
In addition to the physical mark withstanding outside conditions, the actual machine has enhanced durability and longevity.
KEYENCE's MD-X, MD-U, and MD-F laser marking machines meet the IP-64 resistance specification. This specification means that water splashing from any direction will have no harmful effect on the machine's use and there will be no ingress of dust, often referred to as dustproof and water resistant.
KEYENCE's MD-X, MD-U, MD-F, and MD-T laser marking machines all have built-in thermopile power monitors.
The thermopile power monitor is an aspect of the laser marking technology that acts as a predictive maintenance tool by measuring the output power of the laser to detect any drops in power over time.
The predictive maintenance will then give a warning about possible malfunctions so that you can proactively fix them before it affects manufacturing processes.
As of , the Food and Drug Administration (FDA) requires all medical devices (besides Class I devices) to display a unique device identification (UDI). The UDI must be readable by machines and humans and contain identifiers like serial, batch number, expiration date, and manufacturing date. Since UDIs store a lot of information on a small device, many businesses choose to use 2D codes.
If you're in the medical sector, incorporating a laser marking system is a sure way to stay in compliance with traceability standards. KEYENCE's laser marking machines outperform alternatives like stamping, labeling, and chemical etching. Laser marking machines can mark the non-geometric shapes of medical devices and do not ever rub off for accidental contamination. These laser marking machines also mark the most common device material, stainless steel.
IPC- requires electronic devices to have traceability about product ID/label, documentation/record keeping, and data exchange/sharing. 2D codes by laser marking machines store over 1,000 characters for the amount of information. Additionally, laser marking machines can mark microscopically yet clearly on small electronic semiconductors. Since laser marking doesn't use force, these fragile materials can be marked without impacting the structural integrity of the part.
Shot blasting is known for creating a perfect finish while covering traceability marks, which is frustrating when you have to redo the mark.
Laser marking technology can mark the 2D codes to be shot blast resistant. By deep engraving the 2D code the depth of the mark will outlast any shot blasting and still be readable afterwards to keep traceability intact.