MeccoMark Laser Systems

A Comparison of Laser Marking Technologies

Table of Contents

How lasers work Comparison of different types of lasers Application examples Cost-benefit analysis Safety

L-A-S-E-R

What is a laser? Its simply the Light Amplification by the Stimulated Emission of Radiation! Now what does that mean and how does that happen?

How Lasers Work

Every object in the universe is made up of atoms. These atoms are constantly in motion; vibrating, moving and rotating. Atoms can be in different states of excitation; either ground state or excited level. In order for an atom (electron) to reach an excited level some type of energy must be applied via heat, light or electricity.

How Lasers Work

Once an electron moves to a higher-state, it wants to return to its original state. When it does, it releases its energy as a photon -a particle of light. These photons of light are what we use in lasers. Although there are many types of lasers, they all have certain essential features. Either a rod or a gas tube is excited by light or electricity (flash lamp, diodes or RF frequency) to release photons of light.

How Lasers Work: Flash Lamp

Laser in non-lasing state

Light from lamp excites atoms

How Lasers Work: Flash Lamp

Some atoms emit photons

Photons bounce back and forth on mirrors stimulating the emission of other photons; laser beam out one end

Types of Lasers

Fiber (Ytterbium) 1070nm CO2 (gas laser) Nd:YAG Flash Lamp (solid state) Nd:YAG Diode Pumped Vanadate (Nd:YVO4)

Fiber Laser
Fiber Coil Ytterbium Collimating optics: straighten beam Beam expansion Diode Cluster

Fiber optic cable Optical isolators: prevent laser beam from traveling back into laser from reflective part Working Distance

Air-cooled fans draw air through

Fiber Laser

XY Axis Galvanometer Motors with Scanning Mirrors Flat Field Focusing Lens

Working Distance Focused Spot Marking Field

Fiber Laser
The fiber laser features the latest in marking technologies, fiber pumping. The laser resonator consists of a fiber bundle that is doped with Ytterbium and pumped with light emitting diodes. The laser light is then fiber delivered to the optical head that consists of a beam expander, collimating optics and back reflection protection. Benefits of a Fiber system:
Available in 10 and 20 Watt models Fiber diodes will last 30,000+ hours No consumables and minimal maintenance Fiber laser can be replaced in the field by customer with no laser alignment necessary Beam quality is higher than Flash Lamp, Diode pumped and Vanadate. High beam quality allows the 10W and 20W laser to match the performance of a 85W laser for most applications Air-cooled design Better Cost of Ownership than Flash Lamp, Diode Pumped and Vanadate system
110V 1-phase, 15A

Q-Switching range from 20 kHz to 80 kHz Smallest footprint of any laser technology. Easy to integrate on existing assembly lines. Can be mounted in any orientation.

Disadvantages of Fiber System:

Q-switching can only go as low as 20kHz. Applications requiring low qswitch frequencies such as deep engraving and some medical plastics will need to use either a flash lamp or diode pumped laser. Small spot size may increase mark time Diodes can be repaired but laser needs to be sent to factory. Estimated cost to repair $2k to $4k

CO2 Laser

Beam Expander

CO2 Gas

Only 1 optic

CO2 Laser
CO2 laser is a gas laser that is used to mark on organic materials such as wood, glass, packaging and plastics. It delivers a non-contrast mark on most materials. Benefits of a CO2 system:
Available in 10, 30, 60 and 100 Watt models Lowest initial costs of all lasers. ~$20k to $25k for 10W system CO2 tube will last 45,000+ hours No consumables and minimal maintenance Air-cooled design Cost to recharge tube is $2k Best Cost of Ownership over Flash Lamp, Diode Pumped, Vanadate and Fiber systems
110V 1-phase, 10A

Small footprint for ease to integrate on existing assembly lines. Can be mounted in any orientation.

Disadvantages of a CO2 system :

Not a q-switched laser. The beam is pulsed but does not deliver peak power. Limited applications. Can remove anodize and paint but can not etch or engrave into metals. Recharge of tube requires laser to be sent back to factory. Alignment of system may need to be performed. Larger spot size than YAG lasers. It has 10x the wavelength of YAG lasers at 10.6 microns. Bigger spot will reduce power density and resolution.
YAG (4.5 field) 25-35 microns CO2 (4.5 field) 300 microns

Flash Lamp: Pros and Cons

Benefits of a Flash Lamp system:

Technology has been developed for over 20 years Field proven design for industrial environments, a true work horse Most versatile and flexible system with variable beam expander, spatial apertures and f-theta lens options. Ideal for job shop environments. Flash Lamp will run for 500 to 1000 hours. Easy to install. Flash Lamp costs $150. Laser Power ranges from 50 to 150 Watts 85W system will cost the same as a 20W diode pumped system Modular design allows for on-site repair Q-Switching range from 1 kHz to 60 kHz

Disadvantages of Flash Lamp System:

Large foot print Must be mounted in the horizontal position Flash Lamp is a consumable Highest Cost of Ownership
208 3-phase, 20A Water cooled (Distilled water reservoir) Chiller required

Diode Pumped Nd:YAG

The diode pumped laser is very similar to the layout of the flash lamp laser. (Refer to previous diagram) Instead of a flash lamp to activate the rod, a cluster of light emitting diodes are used. Benefits of a Diode Pumped system:
Diode Pack requires no consumables and minimal maintenance Diode pack lasts between 5,000 to 10,000 hours Versatile and flexible system with variable beam expander, spatial apertures and f-theta lens options. Laser Power ranges from 20 to 100 Watts High beam quality allows the 20W laser to match the performance of a 85W laser for most applications Water cooled, but has built in chiller. (Flash lamps require external chiller) Better Cost of Ownership than Flash Lamp system
208 1-phase, 15A Water cooled (Distilled water reservoir)

Modular design allows for on-site repair Q-Switching range from 1 kHz to 60 kHz Smaller footprint than Flash Lamp (38 length versus 54 length)

Disadvantages of Diode Pumped System:

Larger foot print as compared to Fiber Must be mounted in the horizontal position Diode Pack replacement costs between $7k and $10k Diode pack can be replaced in field but may require laser alignment Higher Cost of Ownership versus Fiber Must be in a controlled environment. Diodes are cooled and held to a constant temperature of 70 degrees Fahrenheit. Ambient temperature higher than 70 degrees will create condensation, which can cause damage to the diode pack.

Vanadate
Very similar to Nd:Yag Diode Pumped Different crystal for rod: Nd:YVO4 Designed to deliver more peak power at higher q-switch frequencies.

Benefits of a Vanadate system:

Higher peak energy allows you to move spot faster but still maintain dot overlapping for continuous line. Smaller package than flash lamp and diode pumped Fiber delivered head allows ease of integration Air Cooled Diode Packs last between 15,000 to 20,000 hours No consumables Better cost of ownership than flash lamp and diode pumped Can be mounted in any orientation Q-switch frequencies from 20 kHz to 200 kHz Runs on 110VAC

Disadvantages of a Diode Pumped system:

Diode pack replacement costs between $5k to $7k No repairable parts in laser head. Must send system back to manufacturer for repair Fixed beam size. No adjustment for beam expansion or focus. Q-switching can only go as low as 20kHz. Applications requiring low qswitch frequencies such as deep engraving and some medical plastics will need to use either a flash lamp or diode pumped laser. Small spot size may increase mark time

Laser Marking Software

What You See Is What You Get (WYSIWYG) Interface Windows based Easy to use, intuitive interface Can easily create text and barcodes
Text: True Type and Stroke Fonts Barcodes: Code 128, Code 3 of 9, 2D data matrix Serialize, Date Codes, Time Stamps

Import graphics directly into software

DXF, WMF, EPS, BMP, JPEGs

Control and apply Laser Parameters Interface to external equipment such as PLCs, XYZ actuators, Rotary Indexers

Laser Marking Software

Laser Marking Types

Engraving

Removing Layer

Carbon Migration

Bonding

Laser etching: Metals

Sample: Surface Etching 2d matrix and text into cast aluminum Summary: All of the YAG based lasers can surface etch on metals. Surface etching is removing less than .001 of material. The Flash lamp can do this the fastest since it has the most peak energy. However the mark time will only reduce by ~10%. The laser best suited for this type of mark is the Fiber Laser due to its low initial cost, cost of ownership and compact size.

Laser engraving: Metals

Sample: Engraving a 2d matrix and text into steel Summary: All the YAG markers can achieve some level of engraving since the laser is removing material. For engraving depths of .003 or greater, the Flash Lamp system is the preferred laser. Since it can deliver 85W or more of power, it can more easily remove the material in the shortest time. Varying the depth is achieved mostly by the # of passes.

Laser marking on Black Plastic

Sample: Color contrast on black automotive plastic w/ YAG Summary: This material requires low power and high q-switch frequency. All YAG lasers can create this contrast. The laser suitable for this material is the Fiber Laser. The Fiber laser delivers a nice contrast on this material and is the most cost effective solution.

Sample: Non-contrast on black automotive plastic w/ CO2 Summary: The 10W or 30W CO2 system is ideal for non-contrast marks on black plastic. The decision over 10W or 30W will be price versus speed.

Laser marking with YAG on White Plastic

Sample: Color contrast on white medical plastics Summary: This material requires a low q-switch frequency in order to create a dark contrast on the white material. The lasers suitable for this material are either the flash lamp or the Vanadate. The Fiber does not have a low enough q-switch frequency to obtain this contrast. The decision of Flash Lamp versus Vanadate will have many factors such as initial costs, Cost of Ownership, other materials to mark etc.

Laser removing layer

Sample # 1: Removing anodize on a tag Sample # 2: Removing black paint on metal Summary: All of the YAG based lasers can remove layers. The Flash lamp can do this the fastest since it has the most peak energy. However the mark time will only reduce by ~10%. A CO2 laser can also remove anodize and paint but the contrast will not be as bright. But it will have enough contrast to create readable barcodes. The laser best suited for this type of mark is either the Fiber Laser or the CO2 laser due to their low initial cost, cost of ownership and compact size. The decision will come down to cost and what other parts are you looking to mark. If you have more metal parts then the fiber is the choice. If you have plastic parts as well then the CO2 is the choice.

Carbon Migration

Sample: Carbon migration (black anneal) on stainless steel Summary: Carbon migration can only be done on stainless steel and titanium. It is a heat treating of the metal to bring the carbon to the surface. All of the YAG based lasers can deliver this mark. The laser best suited for this type of mark is either the Fiber Laser or Vanadate. The decision will come down to price versus mark time. The Fiber will have the longest mark time but will be the least expensive. The Vanadate will be able to increase your mark time but has a higher initial cost.

Laser bonding

Appropriate for metals,glass, and ceramics This marking process is good for Safety critical hardware High temperatures Salt fog/spray environments

Step 1 Coating Applied And Bonded to Surface Using Laser

Step 2 - Unmarked Coating Removed

Laser bonded sample

Sample: laser bonded material to metal or plastics. Summary: For laser bonding, the two lasers best suited for this are either the 10W fiber laser and the 10W CO2 laser. As with carbon migration, this is a heat treat process that does require time to heat and bond the material.

Laser marking with CO2

Samples: Marking cardboard, wood, labels and glass with a CO2 laser Summary: The CO2 is ideal for marking on organic materials such as cardboard, labels, wood and glass.

Ballpark Laser Prices

10W CO2 10W Fiber Pulsed 20W Fiber Pulsed 20W Vanadate 20W Diode Pumped 85W Flash Lamp

$20K $42K $50K $58k $60k $58K

Cost of Ownership
Flash Lamp
Electrical Requirements Cooling Requirements kW per hour 208 VAC, 3 Phase, 50/60 Hz, 30A Water, external chiller or factory water required 6 kW

Diode Pumped
208, Single Phase, 50/60 Hz, 20A Water, built-in chiller 2 kW

Vanadate
90-240VAC, Single Phase, 50/60 Hz, 10 A Air

Fiber
90-240VAC, Single Phase, 50/60 Hz, 10 A Air

CO2
90-240VAC, Single Phase, 50/60 Hz, 10 A Air

.7 kW

.18 kW

.3 kW

Lasing Activation Hours per lasing medium Cost to repair

Flash Lamp

Diodes

Diodes

Diodes

Gas

500 to 1,000 hrs per flash lamp $145 per flash lamp 500 hours per flash lamp 1 year per rod
(rod life time ~ 8 to 10 years)

5,000 to 10,000 hrs per diode pack $7k per refurbed diode packs 5,000 hours or 1 year

15,000 to 20,000 hrs per diode pack $7k per diode pack 10,000 hrs or 2 years

30,000 to 50,000 hours per diode pack $2k per diode pack 17,500 hrs or 2 years

45,000 hrs per tube $2k for tube recharge 17,500 hrs or 2 years

Warranty

Cost of Ownership

Flash Lamp
5 year cost of electricity (@ $.10 kWh running 24/7) Cooling Requirement Costs 5 Year cost of consumables (24/7) 5 Year Total Cost of Ownership (24/7) 1 Year Total Cost of Ownership (based on 5 year
model)

Diode Pumped
$8760

Vanadate
$3,066

Fiber
$788.00

CO2
$1314

$26,280

$26,280 (6kW for chiller) $12,702

No additional, built-in chiller $30,660

Zero (Air) $20,440

Zero (Air) $6,000

Zero (Air) $1,946

$65,262

$39,420

$23,506

$6,788

$3,260

$13,052

$7,884

$4,701

$1,357

$652

Why Laser Mark?

Permanent mark on variety of materials Non-contact to part Repeatable every time Software allows user to easily add, change and delete text, graphics, barcodes, etc Minimal consumables as compared to ink jet and pad printing Cost effective

Labels vs. Laser Marking

EAV: 367,000/yr at 5 years 10W Fiber Laser

Label Cost Stick-On Label $.10

Labor Cost
4 sec x $0.0042 x 367,000 = $6,166

Label/ Mark Machine $10,140

Annual Cost $42,866

1 Yr Total $53,006

5 Yr Total

$224,470

Laser Marking

Zero

Zero, automatic process

$71,420

$1,357

$72,777

$78,205

5 year savings of $146,265

Automatic Identification & Data Management

Laser Integration
OEM
Size/cost/performance improvements ROI/value for your customers

End users
Stand alone work stations Turn tables/conveyors Rotary X/Y/Z motion

Laser Safety

Laser Integration is governed by both Center for Device and Radiological Health (CDRH) and ANSI standard Z136.1 2000 Both specifications main purpose is to warn the operator of the level of laser radiation and protect the operator or persons inside the Nominal Hazard zone from exposure. Lasers are rated at different classifications based on the level of exposure.

Laser Safety
Class 1 Class I lasers are low powered devices that are considered safe from all potential hazards. Some examples of Class I laser use are: laser printers, CD players, etc. No individual, regardless of exposure conditions to the eyes or skin, would be expected to be injured by a Class I laser. Class II lasers are low power (< 1mW), visible light lasers that could possibly cause damage to a person's eyes. Some examples of Class II laser use are: classroom demonstrations, laser pointers, aiming devices and range finding equipment. If class II laser beams are directly viewed for long periods of time (i.e. > 15 minutes) damage to the eyes could result. Avoid looking into a Class II laser beam or pointing a Class II laser beam into another person's eyes. Avoid viewing Class II laser beams with telescopic devices. Realize that the bright light of a Class II laser beam into your eyes will cause a normal reaction to look away or close your eyes. This response is expected to protect you from Class II laser damage to the eyes. Class IIIa lasers are continuous wave, intermediate power (1-5 mW) devices. Some examples of Class IIIa laser uses are the same as Class II lasers with the most popular uses being laser pointers and laser scanners. Direct viewing of the Class IIIa laser beam could be hazardous to the eyes. Do not view the Class IIIa laser beam directly. Do not point a Class IIIa laser beam into another persons eyes. Do not view a Class IIIa laser beam with telescopic devices; this amplifies the problem. Class IIIb lasers are intermediate power (c.w. 5-500 mW or pulsed 10 J/cm) devices. Some examples of Class IIIb laser uses are spectrometry, stereolithography, and entertainment light shows. Direct viewing of the Class IIIb laser beam is hazardous to the eye and diffuse reflections of the beam can also be hazardous to the eye. Do not view the Class IIIb laser beam directly. Do not view a Class IIIb laser beam with telescopic devices; this amplifies the problem. Whenever occupying a laser controlled area, wear the proper eye protection. Class IV lasers are high power (c.w. >500mW or pulsed >10J/cm) devices. Some examples of Class IV laser use are surgery, research, drilling, cutting, welding, and micromachining. The direct beam and diffuse reflections from Class IV lasers are hazardous to the eyes and skin. Class IV laser devices can also be a fire hazard depending on the reaction of the target when struck. Much greater controls are required to ensure the safe operation of this class of laser devices. Whenever occupying a laser controlled area, wear the proper eye protection. Most laser eye injuries occur from reflected beams of class IV laser light, so keep all reflective materials away from the beam. Do not place your hand or any other body part into the class IV laser beam. The pain and smell of burned flesh will let you know if this happens. Realize the dangers involved in the use of Class IV lasers and please use common sense.

Class II

Class IIIa

Class IIIb

Class IV

Laser Safety

Protective Housing:

The protective housing must prevent human access to laser radiation in excess of the limits of Class I at all places and times where and when such human access is not necessary in order for the product to accomplish its intended function. Safety interlocks must prevent human access to laser or collateral radiation that exceeds the limits of Class I when a protective housing is opened during operation or maintenance. Safety interlocks in Class IV systems must be redundant or fail safe. Defeatable interlocks must provide an audible or visible indication of defeat. They must also not allow the cover to close and still be in the defeated position. The purpose of a remote interlock connector is to permit the user to connect a remote barrier interlock, emergency stop switch or similar device. The circuit must be such that, when the terminals of the connector are open, human access to laser radiation is prevented. A key control is required for Class IIIb and IV systems in order for the user to prevent unauthorized operation. The key must not be removable in the "on" position. An emission indicator is required on Class II, IIIa, IIIb and IV laser systems. The indicator can be visible or audible. On Class IIIB and IV laser systems the indication must precede emission by a length of time sufficient to allow users and others in the area to recognize that the product has been energized so they can avoid exposure. Emission indicators must be duplicated on lasers (heads) and operation controls if they are capable of being separated by greater than 2 meters.

Safety Interlocks:

Remote Interlock Connector:

Key Control:

Emission Indicator

Laser Safety

Safety Shutter

A beam attenuator (shutter) is required on Class II, IIIa, IIIb and IV laser systems. The beam attenuator is a mechanical or electrical device such as a shutter or attenuator that blocks emission. The beam attenuator blocks bodily access to laser radiation above Class I limits without the need to turn off the laser. The beam attenuator must be available for use at all times during operation. Operating controls on a Class II, IIIa, IIIb or IV laser product must be located such that it is not necessary for the user to be exposed while manipulating them. A manual reset is required on Class IV laser systems. It must prevent automatic restart after an interruption due to remote interlock activation or from an interruption for more than 5 seconds due to unexpected loss of main power. A warning logotype is required for Class II, IIIa, IIIb and IV laser products. Removable or displaceable protective housings that are not safety locked or that have defeatable safety interlocks also require warning labels. Labeling must be visible on the product prior to and during removal or displacement of the housing and close to the opening involved. An aperture warning label is required for each aperture through which laser radiation in excess of Class I or IIa. A certification label is required and must state that the manufacturer certifies that the product complies with the standard or with an approved variance. An identification label must be provided and must contain the name and address of the manufacturer and the place, month and year of manufacture; the month and year of manufacture may not be abbreviated.

Operating Controls Manual Reset

Safety Labeling

Laser Safety

Nominal Hazard Zone

The nominal hazard zone (NHZ) describes the space within which the level of direct, reflected, or scattered radiation during normal operation exceeds the appropriate MPE's and is determined from the following characteristics of the laser:
Power or energy output. Beam diameter. Beam divergence. Pulse repetition frequency (prf). Wavelength. Beam path including reflections. Beam profile. Maximum anticipated exposure duration

MAXIMUM PERMISSIBLE EXPOSURE (MPE)

The level of laser radiation to which person may be exposed without hazardous effect or adverse biological changes in the eye or skin.

Laser Safety
Protective Housing: Light Tight: No direct exposure from laser light. Laser must take more than 1 bounce or reflection to harm operator Overlapping of panels on any access point Safety Interlocks (2x) on doors or access panels to the laser enclosure/zone Viewing windows are available in both glass and plastics. Substrates are coated for specific wavelength of laser. Emission and shutter indicators. Must file Class 1 enclosure with CDRH