Laser Digital Etch Processing - The Challenge to Traditional Die-cutting

The laser digital etching process refers to etching the processed material by laser beam (vaporization of the material irradiated by the laser) according to the digitized information, instead of the traditional die-cutting process.

Typical laser digital etching systems include: carbon dioxide lasers and scanners, power units, coolers, power controllers, software, smoke chambers, etc., if not integrated with printing machinery or processing lines, then there are processing rolls. Operational system: The processing of high registration accuracy may also require an electronic display control system. The general estimate is that the investment will be between 180,000 and 300,000 U.S. dollars.

In the old system, the laser was fixed, and the material processing table was moved in the X and Y directions, so the speed was limited and it was difficult to welcome. The new system uses a scanning galvanometer to drive the laser beam and the rotating mirror so that the laser beam can be fired in all directions, and the processing speed is also greatly increased, which can reach a range of 80 to 600 inches per second. For the reel-to-reel laser processing system, it is also possible to perform intermittent repetitive processing, ie, laser beam is intermittently repetitively processed according to the programmed pattern information (as in the case of a continuous dryer). For the etching depth of the material to be processed, as long as the etching speed or laser parameters are adjusted, it can be flexibly adjusted (or completely penetrated, or lightly spotted, used for indentation or film removal).

Obviously the advantages of this new laser digital etching process are easy to understand;

1. Flexibility: In any shape, there is no need to make a mold. As long as a program is prepared, the laser beam will be able to follow the procedure to shape the shape and depth of the “die-cut”, and it can also be changed in operation without the need of “tools”. This opens the door to personalized or small batches of packaged goods or trademarks.

2, the accuracy is good: the tolerance does not exceed three thousandths of a millimeter. It also compensates for errors that occur between printing and post-processing because lasers can compensate for adjustments, whereas in conventional die-cutting, the die is difficult to change after it is fixed.

3, the production efficiency is high: Because does not need to make the mold, only needs to make up the procedure, the task carries on with the follow-up, saves time and saves time. Adjustments can also be made at the last minute before starting processing without affecting production. Regardless of simple or complex machining shapes, the processing costs are the same and the time taken is basically the same. Its processing speed can basically match with the speed of digital printing, and can form a continuous machine production.

4. Economic benefits: It is not necessary to prepare molds, and the processing tasks can be performed in large batches or small batches, and the business sources can be broadened. In the traditional die-cutting process, not only the die variety (such as flat pressure type, wheel pressure type, hole punching, eye-opening, indentation, etc.), but also the supporting tools are complicated. Now all can be omitted.

5, beautiful effect: laser etching is no pressure, so no traces on the material after processing; pressure-sensitive trademark not only does not see the indentation, but also easy to peel.

From the point of view of technology, although it has the above advantages, the current promotion and application are still the initial class. Several manufacturing companies have launched related equipment, such as: LaserSharp, Lightening Bolt, Softdie, AcuTear, AcuBreather, etc., are all registered patents. However, when users introduce such devices, they are often reluctant to make them known to the public. They even sign a confidentiality agreement with their suppliers to maintain their technological leadership.

The devices that have been introduced also have certain characteristics. Such as: Softdie system, is for the trademark market, so the use of multiple laser beam scanning to increase the etching speed to 600 ips, can match the speed of the trademark printing press, off-line processing, of course, no problem. The AcuTear and AcuBreathe systems were launched in early 2000 for the flexible packaging market, allowing multi-layered composite film packages to be indented or microporous without compromising the package's sealing performance. Experts also pointed out that making micropores in flexible packaging and making it breathable is almost impossible in rotary molding because it cannot be carved so small and smooth, and there are often residues that block micropores but use lasers. Etching is not a problem.

The emergence of new technologies certainly cannot be perfect at once. In some cases, it is still necessary to continue research and improvement. For example: the variety of packaging materials, thickness varies, performance will also have access, laser etching, how to etch the residence time or laser energy, grasping just right, so that the edge of the etching smooth, deep and shallow, there is also a never-familiar to Skilled process. In addition, there are certain limitations, such as: metal material is not suitable; there are certain deficiencies, such as: laser incision microstrip bevel, some materials may change color, some plastic may be slightly visible burrs and so on.

In general, however, some experts predict that within 10 years, the traditional die-cutting process may disappear in some large packaging and processing companies: In the vast market of packaging products, laser etching processing will be increasingly welcomed and promoted. This is another leap in laser technology for "die cutting."