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SYNRAD, INC. - http://www.synrad.com |
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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. |
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Adding a 20% to 30% glass fill to nylon formulations increases the blend’s stability, rigidity, and wear-resistance. In many cases, the glass fiber also helps to increase contrast on plastic materials that are CO2 laser marked. Although the percentage of glass fill in this nylon gear does not increase mark contrast drastically at low power levels, it still provides an increase in contrast and readability over pure nylon. Our marking setup consisted of a Synrad sealed CO2 laser coupled to an FH Series marking head and driven by our WinMark Pro laser marking software. We installed a 125 mm focusing lens on the head to obtain a 180-micron (0.007”) spot with a 3 mm (0.118”) depth of focus over the extents of the mark field.
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We opened a new drawing in WinMark Pro and created a seven-character part number using Simple, one of WinMark’s twelve built-in stroke fonts, and then set a Text Height value of 4 mm (0.158”). On the Marking tab, we set a Power—duty cycle percentage—corresponding to 25 watts and a Velocity of 508 millimeters per second (20 inches/sec). Using these settings, we were able to mark these components at a rate of 0.14 seconds per part. As shown in the photo, the glass-filled nylon part exhibits a readable engraved mark with some contrast. |
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Adhesive backed high-density foams are used in many industrial and consumer products to seal against moisture, light, and dust. These foams provide electrical and thermal insulation properties in addition to cushioning against vibration and shock. The laser process requested for this application was for a kiss-cut—a process where the laser cuts through the high-density foam (or other material) without cutting the paper liner. Achieving a successful kiss-cut involves finding the proper balance of laser power and motion to obtain consistent cuts through the material without damaging the backing or liner. This is especially crucial in web converting or labeling applications where significant downtime is incurred if the liner (web) is cut or broken and must be rethreaded through the machine. |
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To perform this test, we setup our XY motion system using a 127 mm (5.0”) plano-convex lens. Based on an incoming beam diameter of 12 mm (0.475”), this lens provides a 180-micron (0.007”) diameter focused spot with a 5.8 mm (0.23”) depth of focus. Although the foam measures 13 mm (0.5”) thick, it exhibits a waveguiding effect that allows the use of a shorter focal length lens while retaining the power density of the smaller focused beam. At a power level of 100 watts with 1.4 bars (20 PSI) of nitrogen assist gas, we cut cleanly through the foam (without damaging the backing paper) at speeds of 3.05 meters per minute (120 inches/min). |
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With hundreds of Synrad CO2 lasers and FH Series marking heads installed on production lines in major glass manufacturing facilities throughout the world, we know a thing or two about glass marking. In the past, we have shared mark parameters that enabled you to achieve the best glass marks possible. In this article, we will describe another method of marking glass that allows you to create laser marks in black or in many other colors. The first photo illustrates a typical 10 watt glass mark, in this case, a logo from our imaginary glass company—the XYZ Window Corporation. This type of mark is by far the most common, a subtle yet readable mark usually seen in the corner of your window panes or door glass. We created the XYZ logo in our WinMark Pro laser marking software by creating two separate text objects and then importing a vector graphic file. In this example, we set the following mark parameters for the first Mark Pass: Velocity – 25 inches per second (IPS), Power – 10 watts, Resolution – 300, Spot Marking Style – Yes, and a Spot Mark Duration of 5 (0.5 ms). We then made two more Mark Passes, changing only the Power setting to 12 watts. By using a 125 mm focusing lens with a 180-micron (0.007”) focused spot, we were able to control and contain the ring fractures to diameters of 200–300 microns. This particular chip-free logo, measuring 45 mm × 35 mm (1.8” × 1.4”), was produced with 10 to 12 watts of power in a cycle time of 7.51 seconds. In cases where a more distinct mark is required (to replace a silk-screened mark on automotive door glass for example) or when creating customized art on glass, the use of proprietary coatings can be used. These coatings, available in several colors, are applied to the substrate (glass, metal, plastic. etc.) prior to marking and then fused to the material surface by the intense heat of the laser’s focused beam, resulting in a permanent bond. |
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The second photo shows our XYZ Window logo after marking another piece of soda-lime float glass. We choose a black coating (available in an aerosol spray), applied it to the glass and then allowed a few minutes drying time. In our mark file, we changed Velocity to 16 IPS, Power to 30 watts, and set Spot Marking Style to No so that we marked continuous vector lines instead of discrete spots. Because we are bonding the coating to the glass surface without inducing fracturing, we set the Mark Passes property to 1. Using these settings to mark the same 45 mm × 35 mm logo, we achieved the high-visibility mark shown at a power level of 30 watts in a cycle time of only 1.97 seconds. By setting power levels between 20–25 watts and velocities of 24–32 IPS, you can also use this same process to mark large, decorative bitmap images on glass using a 370 mm lens (0.021” focused spot) over an area as large as 9.5 × 11.7 inches. When raster-scanning bitmap images, lower powers at higher speeds create the same permanent bond without heating the glass to a point where uncontrolled fracturing occurs.
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Search our online library for more applications of Synrad's sealed CO2 laser technology. Sort by material, process, or industry. |
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Happy Holidays from Synrad! Our next Applications Newsletter will be e-mailed |
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Synrad, Inc. 4600 Campus Place Mukilteo, WA 98275 Tel: 1-425-349-3500 Fax: 1-425-349-3667 E-mail: synrad@synrad.com |
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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. |
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