Finding the optimal solution for your production needs
In the dynamic environment of a modern shop floor, laser marking technology has radically transformed the processes of identifying and tracking components. However, navigating through the sea of available options can be disorienting, especially when the goal is to find the system that fits perfectly with the specific needs of one’s manufacturing operation.
Choosing the ideal laser marker is based on a careful evaluation of interconnected factors that will determine the effectiveness of the investment. This guide reviews the key criteria to consider in selecting the system best suited to your specific needs.
The material dictates the technology: which laser for which applications
The first discriminating factor in choosing a laser marker is the type of materials to be processed. Metals, for example, respond excellently to fiber lasers, which with their specific wavelength can effectively penetrate metal surfaces creating durable, high-contrast markings.
For aluminum, a material that is more refractory to marking than steel, fiber lasers with powers from 30W to 50W are generally recommended, combined with relatively short focal lengths that concentrate energy at a precise point. This configuration allows for perfectly readable datamatrix codes (DMCs) even after surface treatments such as sandblasting.
Plastics, on the other hand, present different challenges. Polymer surfaces can react in unpredictable ways to laser radiation, which is why choosing the right wavelength becomes critical. UV lasers excel on materials such as PMMA or ABS, while green light diode lasers (ONDA or Wave system) offer amazing results due to their extremely short but energetic pulse, which allows plastics to be marked without additives while avoiding carbonization or thermal deformation.
In any case, in more than 90 percent of cases, the fiber laser (often in its MOPA version) is the preferred choice for workshops because it can provide excellent versatility and meet the most common demands of the industry, as well as offering excellent price/performance ratio.
The mechanical configuration according to production volumes
The required productivity significantly determines the most suitable mechanical configuration. For a low-volume shop (50-200 parts/day), a Z-axis-only system is often the most economical and effective solution. These systems allow the height of the marking head to be adjusted relative to the part, ensuring proper focus, but require manual repositioning of the part for markings on different areas.
As production volumes increase (200-500 parts/day), two-axis (XZ) systems become preferable. The addition of the X axis allows larger areas or more parts to be marked simultaneously without manual repositioning. This configuration can increase productivity by up to 25 percent over Z-axis-only systems.
For high productions (over 500 pieces/day), more advanced configurations come into play:
- Rotary table systems: They work in masked time, allowing parts to be loaded/unloaded while others are being marked, eliminating downtime.
- Systems with XYZ axes: The addition of the Y axis further expands the work area, allowing entire pallets of components to be marked in a single cycle. A marker such as the CompactMark, equipped with three linear axes, can process pallets containing dozens or hundreds of parts, dramatically reducing the cycle time per component.
Component geometries and special configurations
The shape and geometric characteristics of the components have a major influence on the configuration needed:
- Cylindrical components or those requiring 360° marking: They require theW (rotary)axis, which allows rotation of the part during marking. This solution is ideal for shafts, rings, ferrules or any component requiring markings distributed around the circumference.
- Non-planar or inclined surfaces: Require a 3-axis scanning head, which allows the optimum focus to be maintained at all times by following the three-dimensional profile of the part. This is especially important for components with curved or multi-level surfaces, where a standard head would produce distorted or blurred markings in areas not perpendicular to the laser beam.
- Heavy or bulky components: For these cases, machines with retractable or side-loading doors, which facilitate handling of parts with lifting systems, are suitable.
- Parts with complex and variable surfaces: Benefit from auto-focus systems that automatically adjust the focal distance according to the morphology of the part. This technology, combined with 3D scanning systems, allows marking of irregular surfaces while maintaining consistent marking quality.
Selection criteria based on specific application needs
Accuracy and tolerances
If the application requires a high degree of precision in marking placement (as in the case of small or tight-tolerance components), it is advisable to opt for systems with a steel frame rather than aluminum. Machines with all-steel construction, such as the CompactMark, offer greater rigidity and stability, ensuring repeatability in the hundredths of a millimeter range.
Production flexibility
For workshops that handle frequent production changes, ease of setup becomes a key criterion. Systems equipped with auto-centering cameras dramatically reduce setup times, allowing rapid changeover from one batch to another without complex manual alignment procedures.
Integration into automated lines
For highly automated manufacturing environments, the ability to integrate with handling systems, robots or assembly lines is crucial. In these cases, in addition to the mechanics of the system, they become crucial:
- Communication protocols: Check compatibility with existing control systems (PROFINET, EtherNet/IP, etc.).
- Customizable software: Ability to develop specific interfaces for communication with corporate MES or ERP.
- Integrated vision systems: To check the quality of marking and send feedback to the control system.
Marking of micro-lots with traceability requirements
For workshops that work primarily to order with variable batches but need full traceability, systems with advanced software that allow:
- Automatic generation of serialized codes
- Historization of markings made
- Association between codes and process parameters
A concrete example: selection of a system for a machine shop
Consider the case of a workshop specializing in machining hydraulic components, with these specific requirements:
- Production: 350-400 pieces/day with peaks up to 600
- Components: Aluminum and steel valves with variable geometries
- Requirements: DMC marking for traceability to automotive standards
- Constraints: Need for double-sided marking of components
Analyzing these requirements, the optimal solution identified is a system with XZ axes and rotating head. This configuration allows:
- Marking in masked time (loading/unloading during processing)
- Ability to process multiple parts simultaneously thanks to the X axis
- Automatic head rotation for multi-sided marking without manual repositioning
The implementation of this solution resulted in:
- 40% reduction in cycle time per component
- Elimination of manual positioning errors
- Ability to handle production peaks without additional resources
Complementary elements that influence choice
Vision systems for quality and positioning
The integration of cameras into the laser marking system is not just an accessory, but something that can significantly influence the choice of system itself. A shop that processes components with high dimensional tolerances or reflective surfaces will benefit greatly from vision systems that allow:
- Self-centering of marking with respect to references on the component
- Automatic verification of marking quality according to standards such as AIM-DPM
- Component type recognition for automatic loading of marking program
Management and customization software
Management software capabilities are another important selection criterion. A system with advanced software enables:
- Manage component databases with associated marking parameters
- Automatically import variable data from external systems
- Program complex marking sequences without manual intervention
- Manage differentiated user profiles for operators and programmers
Suction and filtration systems
For applications that generate significant amounts of dust or fumes (such as deep marking on aluminum), the quality of the suction system becomes a determining factor. Inadequate suction can compromise not only the quality of the marking but also the life of the system’s optical components.
Considerations for future developments
In selecting a laser marking system, it is critical to consider not only current needs but also possible future developments in the workshop. A forward-looking choice will evaluate:
- System modularity: Ability to add axes or accessories at a later date
- Software upgrade: Availability of software upgrades to implement new features
- Service and support: Presence of qualified technical service and availability of spare parts
A system that allows incremental evolutions enables investment to be deferred over time, adapting to changing production needs without the need for complete replacements.
Choosing a technology partner
Selecting the ideal laser marker requires a deep understanding not only of the available technologies, but also of the specific current and future production needs of one’s workshop. In this decision path, the supplier’s role ideally becomes that of a technology partner, capable of analyzing processes, proposing tests on real components and suggesting the most suitable configuration.
LASIT accompanies its customers along this path through marking tests on actual components, analysis of production flows, and support in integration with existing systems, ensuring that the final solution is not simply a laser marker, but a system perfectly tailored to the specific needs of each production reality.