 |
|
|
|
|
 Marking FR4 PCBs
|
Glass Marking with FH Flyer |
Cutting Ceiling Paper |
|
SYNRAD's sealed CO2 lasers are used in a variety of industrial processes including cutting, welding, drilling, and marking. This news brief showcases some of the interesting materials and products that are processed daily by Synrad's line of CO2 lasers and marking heads.
|
|
 |
Marking FR4 Printed Circuit Boards
Circuit boards, like most components in the modern manufacturing supply-chain, are bar-coded for tracking purposes throughout the process, from raw board creation to final assembly. Common bar coding solutions for FR4 printed circuit boards (PCBs) include laser marking, ink-jet printing, or affixing pre-printed labels. In a production environment, especially where a larger parent board contains many smaller boards, it is often useful to mark as many individual PCBs as possible before part movement is required. This reduces overall processing time, which leads to more efficient throughput.
SYNRAD's FH Flyer marking head, equipped with a 370 mm focal length lens, provides our largest available mark field, with a nominal field size of 198 mm by 198 mm (7.8" x 7.8"). This is an ideal marking setup for large arrays of parts, such as PCBs.
For this application, Flyer was paired with a 48-1 laser and controlled by our WinMark Pro laser marking software. An 8 by 8 array of 2D codes, measuring 6.35 mm (0.25") square, with individual cell sizes of 0.48 mm (0.018"), was marked. Because of the large spot size (0.54 mm or 0.021") of the 370 mm focal length lens, the minimum cell size should be no smaller than 0.48 mm (0.018"). This factor must always be considered before specifying a 370 mm lens for marking 2D codes. |
|
|
|
In WinMark Pro, we created a 2D code object and entered the 10-character data. The 2D Barcode Bitmap property was set to "No" and the 2D Barcode Circle Radius was set to 9%. On the Marking tab, we set a laser power of 10 W at a Velocity of 254 millimeters per second (10 in/sec). The 2 mm (0.08") high human-readable text was marked at a power of 10 W and Velocity of 381 mm/second (15 in/sec). The total cycle time to mark all 64 codes was 20.07 seconds with cycle times of 0.31 seconds to mark individual codes. The array of 2D codes were read and easily verified using a Microscan Quadrus EZ system, achieving overall "A" grades per the AIM grading method.
|
|
|
Glass Marking with FH Flyer
With the FH Series Flyer marking head, we can produce many marks at cycle times that are 1.5 to 2 times faster than with the previous FH Index/Tracker heads. This is due in part to the faster speeds and quicker response of Flyer's optical scanners. For example, we had previously tested a high-speed tracking application for a customer in the glass industry who was attempting to mark glass at a rate of 60 feet per minute (FPM). Because the mark had many elements, including a logo and 65 text characters, we could not meet their line speed requirements. When Flyer was released, we retested their application using the Flyer marking head. The results? Flyer easily exceeded the customer's line speed requirement by 45%. |
|
|
This mark, consisting of an outline EPS graphic along with TrueType and stroke text, was marked in a cycle time of 0.39 seconds using 90 watts of power with the FH Flyer marking head.
|
To demonstrate, we created a mark file for a hypothetical glass company - XYZ Windows - and tested the file on both FH Tracker and FH Flyer marking heads. We set up our Flyer head with a 200 mm focusing lens that produces a 290-micron (0.011") spot over a maximum mark field of 165 mm (6.5"). For laser power, we choose a Firestar t100 laser in order to achieve the power density necessary to mark glass at velocities over 18.3 meters/min (60 FPM).
For the FH Tracker head, we set up our mark file to mark at a speed of 2540 millimeters per second (100 inches/sec) at a power level of 90 watts. Using these settings, we marked the entire 31 mm x 30 mm (1.22" x 1.18") image in a cycle time of 0.59 seconds. With a 200 mm lens, this equates to a maximum line speed of 13.7 meters/min (45 FPM).
We then set up an FH Flyer marking head using the same lens, power (90 watts), and Velocity (100 IPS) settings as before. The only other file modifications were due to Flyer's faster response times - decreased object delays, an increase to the Off Vector Velocity, and a decrease in the stroke text object's PWM frequency (FH Flyer and WinMark Pro v5 allow you to vary PWM frequency by object!). With a cycle time of 0.39 seconds per mark, we can now reach a maximum line speed of 20.7 meters/min (68 FPM). This speed is approximately 50% faster than our previous attempt, and is 13% faster than our desired line speed of 60 FPM.
|
|
|
Cutting Ceiling Paper
Ceiling paper is frequently seen in traditional or Victorian homes and manors. Much like wallpaper, ceiling paper is available in subtle textures, embossed designs, and multi-color printed designs. This application request involves laser cutting various textured ceiling papers to size. We laid out paper samples on our XY table and installed a 63.5 mm (2.5") positive meniscus lens into the cutting head. This lens focuses the incoming beam down to a 100-micron (0.004") spot with a 1.8 mm (0.07") depth of focus. An assist gas port below the lens directs 1.4 bars (20 PSI) of clean, dry air coaxially with the beam down through the nozzle.The white textured paper, measuring 0.18 mm (0.07") thick, was cut using 100 watts of power at a linear cut speed of 50.8 meters per minute (2000"/min). The cut edge is clean and shows no sign of charring on the cut edge or top and bottom surfaces.
|
|
|
These textured ceiling papers were cut using
100 watts of power at 2000 inches per minute
(white sample) and 1000 inches per minute (tan sample). Although the tan paper shows some discoloration on the cut edge, the white sample demonstrates an exceptionally clean cut. |
The tan textured paper, 0.36 mm (0.014") thick, was also cut with 100 watts of power. Maximum cut speed was 25.4 meters per minute (1000"/min), however this material exhibits some slight discoloration of the cut edge as well as the upper surface.
|
|
|
|
|
FH Flyer / Fenix Flyer Technical Updates
Synrad Technical Updates keep you informed of recent developments related to FH Flyer Marking Head or Fenix Flyer Laser Marker products. Sign up to receive these bulletins automatically via email at http://www.synrad.com/FH_Flyer/flyersupport_subscribe.htm
|
|
|
Contact Us:
Please do not reply directly to this newsletter. E-mail questions or comments to synrad@synrad.com
Synrad, Inc.
4600 Campus Place
Mukilteo, WA 98275
Tel: 1-425-349-3500
Fax: 1-425-349-3667
E-mail: synrad@synrad.com
|
|
|
|
|
Copyright ©2009 SYNRAD, Inc. All rights reserved.
SYNRAD and Synrad product names are trademarks or registered trademarks of SYNRAD, Inc. All other trademarks or registered trademarks are the property of their respective owners.
|
|
