The need: reliability and precision in the foundry industry
Endurance is a global player with significant presence in Europe since 2006, which has been gradually strengthened by the acquisition of several foundries, including FOA in 2012 and Fonpresmetal GAP in 2019. With more than 50 presses ranging from 400 to 2,700 tons and more than 400 mandrels, the company produces more than 30 million automotive parts annually.
Endurance’s need was to implement laser marking systems that would ensure high accuracy in marking datamatrix codes on die-cast aluminum components, with automatic quality verification according to AIM-DPM standards. Complete integration with existing production systems, adaptability to non-uniform surfaces typical of foundry processes, and resistance to complex industrial environments were also critical.
A versatile and multifaceted partnership
The collaboration between LASIT and Endurance, which began in 2019, has developed through multiple applications ranging from the integration of simple lasers to the implementation of complete customized systems. In recent years, LASIT has supplied and integrated more than 20 laser systems into Endurance’s production lines, with main installations in the Lombardore and Chivasso plants.
“Working with LASIT has enabled us to optimize our component traceability processes, resulting in a significant increase in production efficiency. The speed of execution of the implemented marking systems, combined with their accuracy and reliability, has been a major competitive advantage for our plants. Particularly appreciated was the flexibility in adapting the solutions to our specific needs, both for high-throughput lines and those dedicated to more complex components. ” – Andrea Tarditi, Technical Director of Endurance.
From laser sources to complete systems: a flexible approach
The uniqueness of this collaboration lies in its flexibility and ability to respond to different production needs. Based on the specific needs of each line, different solutions were implemented. On the one hand, the integration of PowerMark lasers into existing lines, complete with vision systems for auto-centering, quality verification of DMC codes and interface with PROFINET protocol. On the other, the provision of complete machines for contexts where a stand-alone system was more convenient, featuring multi-axis systems and advanced quality control technologies.
Powers and applications: optimized speed and performance
The versatility of the collaboration is reflected in the range of laser powers implemented, which vary from 20W up to 200W. This choice was driven primarily by the need to optimize the speed of production cycles while maintaining the high quality of marking.
The selection of optimal power was made by considering:
- Cycle speed required by the production line
- Type of material to be marked (different aluminum alloys)
- Subsequent treatments to which the component would be subjected
More powerful lasers (100-200W) have been implemented in high-throughput lines, where reducing cycle times by even a few seconds results in a significant increase in overall production capacity.
Integrated technologies for quality control
A key aspect of the collaboration was the integration of multiple advanced vision systems into all implemented solutions. These systems employ high-resolution cameras with image-processing algorithms that enable not only self-centering of marking with micrometer accuracy, but also dimensional verification of components to tenth-of-a-millimeter tolerances.
The most advanced systems integrate up to four strategically placed cameras to perform comprehensive three-dimensional inspections and ensure the 360-degree quality of the marking process. Interfacing collected data with Endurance’s quality management systems enables complete traceability and statistical monitoring of processes.
Integration into production processes
The real challenge in implementing these systems has been their seamless integration into existing production processes. This has been made possible by the use of standardized industrial communication protocols, mainly PROFINET, which ensure reliable data exchange with Endurance control systems. Specially developed custom software allows direct interfacing with MES/ERP systems, ensuring continuity of information flow from design to production.
Concrete results
The implementation of these solutions has led to significant improvements in Endurance’s production processes:
- Reduction of waste by more than 15% due to integrated quality control systems
- Increased production flexibility with reduced setup times between different productions
- Increased overall productivity by optimizing cycle times
Each component produced is now uniquely identifiable through high-quality datamatrix codes, while the elimination of consumables compared to traditional systems such as pad printing has generated significant savings and reduced environmental impact.
Ongoing support as a success factor
A key element of this collaboration has been the ongoing support provided by LASIT through rapid technical assistance from its Burago di Molgora (MB) headquarters, ongoing training of Endurance personnel and periodic optimization of marking parameters. This approach has enabled the joint development of new solutions for specific needs, creating a virtuous circle of shared innovation.
Future developments
The collaboration between LASIT and Endurance continues to evolve, with new implementations involving artificial intelligence marking systems for automatic component recognition and deeper integration with Industry 4.0 systems. High-speed marking solutions are also being developed that will further increase productivity and the implementation of green laser technologies for specific applications on particular materials.