Laser marking on die-cast components

Until a few years ago, laser marking on unfinished components that had just come out of a die was not achievable due to the qualitative degradation caused by subsequent processes—in particular DataMatrix codes.

Today, however, the development of more powerful laser markers has allowed us to meet manufacturers’ requirements while providing permanent and complete traceability. This is particularly the case when the laser marking of components happens immediately after leaving the die.

Thus, we are able to guarantee the DataMatrix code readability even after invasive processes such as sandblasting or shot peening.

LASIT has developed several solutions for foundries. Our offering includes standalone systems and automation through in-line integration laser marker machines.

Specifically, our solution portfolio encompasses 24 systems designed in the last ten years to provide for loading/unloading during downtime, as well as 5 special stations for robotic integration. Furthermore, the strength of these laser markers lies in the productivity resulting from cooperation with the robot.

Custom software

Autofocus

Vision systems

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Laser Marking Before Sandblasting

If we consider the processes to which a die-cast component is subjected, the most interesting ones are certainly sandblasting and shot peening.

Although both steps are indeed necessary in the processing cycle, their invasiveness jeopardizes the DataMatrix code (and therefore its readability).

LASIT has developed a strategy to prevent the DataMatrix code from becoming unreadable after various processes.

This was possible thanks to deep markings with specific parameters and dedicated geometries, specifically designed for die-cast components. High-power lasers i.e. 100W, 200W or 300W are most commonly used here because they also guarantee an extremely fast process.

Ensuring Laser Marking Quality after Sandblasting

Our research to produce A-Grade results even after the sandblasting process: real parameters and tests on metal samples

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Robot Integration

LASIT is an expert in customization of laser systems designed to meet all customer requirements. We have delivered many complex projects and integrated solutions— with our goal being not just to sell a product but to find real solutions to real problems. True to this principle, over the years we have excelled in our field thanks to our outstanding automation capacity and versatility. For die-cast components, in particular, we specialize in the production of integrated systems.

A notable example was the laser marking system made for engine blocks. The laser marker consists of a cell with three inlets. Each inlet features a shuttle to load the component to be marked.

The core of the system is a six-axis ABB robot integration that can attain any position. Thus, the die-cast can reach the laser engraving cabinet from any direction. Regardless of its orientation, the laser will find the correct position for laser marking.

This is accomplished through the 3D scanning system. This system checks the shape of the die-cast component and its position on the shuttle.

The vision system consists of a camera attached to the marking head. The camera identifies the die-cast, the location of the marking, and the area to be marked, so that the laser marker engraves the code at the exact point.

As the die-cast enters the cell, the robot positions the 3D marking system to scan it completely. The result is a complete 3D photograph of the piece, which allows us to uniquely identify the piece within the laser marker database.

At this point, the software instructs the robot to move to the desired marking position, regardless of the piece’s orientation on the surface. Meanwhile, the marking layout is sent to the laser, updating the DataMatrix’s content with data taken from the customer’s factory system. Just before marking starts, a laser measurement system adjusts the robot position to ensure laser focus.

This extraordinary system also reads and grades marked codes. Operators can view the result directly on the monitor. Then, they can then pull out the marked die-cast and start the cycle again without interruption.

The cabinet houses a camera for inspection purposes. This records all activities to identify the causes of potential malfunctions.

Laser Marking During Downtime With Robot Integration

FlySwap is another interesting solution developed by LASIT for laser marking of die-casts. This laser marking system is designed to work with robot integration to load large pieces. The double loading station does not have a rotary table. It has been developed to facilitate loading and positioning from above through a mechanical arm.

The upper door is pneumatic and free from clutter. The 580×330 mm surface is designed for large die-castings and for positioning custom pallets.

The role of a distance sensor is key, as it helps the laser marker correct micro-focusing distances due to printing inaccuracies of the die-cast. Thus, the laser marking machine always guarantees an optimal result.