Everything You Need to Know About Laser Etching

Speed and durability are the factors that make laser etching suitable for marking applications.

So, in this article, we’ll learn everything about laser etching – how does it work? What kind of materials can you etch? Why should you brand spare parts like Trumpf spare parts or Prima spare parts? What are the various types of laser etching? And how to implement it?

Let’s start by understanding the laser etching process. 

What is Laser Etching

It is a process that melts the surface of the material and creates marks on it. It belongs to the category of laser marking that also includes laser engraving and laser annealing. Laser etching is highly versatile and can be used with most metals.

It is mainly used to produce permanent markings such as data matrix codes, serial numbers, barcodes, and logos. 

How Does Laser Etching Work

Whichever laser marking method you use, there’s one thing common in all. The laser beam is pulsed, which then releases sudden bursts of energy at specific time intervals. A 100W laser pulse can release 100,000 pulses within a second. Each pulse consists of 1 millijoule of energy and can reach a max of 10,000W power.

In laser etching, the metal requires less energy than engraving. Hence, in etching, the pulses are more distant compared to engraving.

For marking, the beam hits the surface, and materials absorb the energy. It reflects most of it while absorbing a proportion, converting it to heat. For laser etching, the material should absorb enough heat to melt the surface and expand. 

When the beam’s energy is transformed to heat, the temperature increases. At such a high temperature, the material becomes malleable, allowing its shape to change.

As the material cools down within milliseconds, the surface roughness of the material changes, making a permanent mark. Also, the color change occurs as a result of permanent marking. For high-quality, black and white make the best contrast. 

This is a generic process. However, each material would have its own course of the process. The process would be optimized and different from the general process. 

What Materials Can You Etch with Laser?

Laser etching is a versatile process, and you can etch almost all the materials. Here are the few from the list of non-exhaustive. 

• Aluminum
• Lead
• Magnesium
• Steel
• Steel Stainless
• Zinc
• Anodized Aluminum

Types of Laser Etching Laser

You can only use fiber lasers for laser etching. The reason is that etching is a process used for metals and thus reacts better with a fiber laser. To be precise, the laser depends on the material you want to etch and not on the marking process.

But why do you exactly need fiber lasers? Let us find out!

Lasers release beams and energy at specific intervals. The material reflects most of the energy while absorbs the remaining, converting it to heat. For etching, the material should absorb enough heat to melt the surface. 

Now, fiber and Co2 lasers generate different wavelengths, and each material reflects these wavelengths differently. To maximize the heat transfer, the material should absorb enough wavelength. If you test it, you will find that material absorbs fiber wavelength more efficiently than Co2 lasers, making it a better choice for marking materials.

Why you Should Choose Branded Spare Parts

We often talk about lasers – how to choose lasers and maintain them. But we forget that a spare part or a consumable is what defines the further use of that laser during a wear-and-tear.

To ensure that the marking quality is as precise as it was in the initial stages, use spare parts such as Trumpf spare parts. These branded parts are high-quality, have better resistance, and don’t wear quickly. As in laser etching, the energy release is high, and the spare parts would ensure that they are high temperature resistant and can withstand energy. 

How to Implement Laser Etching

Consult an expert that offers laser marking machines and OEM laser markers. Specify your requirements and take their guidance about the same.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/everything-you-need-to-know-about-laser-etching

Tips to Improve CNC Plasma Quality

Achieving better quality is the ultimate goal of plasma technology. 

For this, you can always ask the customer support team for guidance or replace the parts with Mazak used parts. However, with proper information and some cool tips, you can improve your plasma cutting quality on your own. 

 Keep reading to learn more!

1. Cut in the Right Direction

Make sure that you cut properly. While using standard consumables, the plasma arc spins in the clockwise direction as the torch moves forward to cut. The squarest angles are on the right side, and thus, contour shapes are cut in a clockwise direction. It is opposite with internal features. There, the torch needs to travel anti-clockwise. So, adjust the current direction if needed. 

2. Refer to the Cut Charts

Check out the cut charts in your system manual and select the appropriate cutting process for your application. Select the process depending on your material type, thickness, desired cut quality, precision, and productivity goals. Based on these details, the cut chart would show the appropriate consumables, amperage, cut and pierce height, shield gases, etc. The arc voltage measurement, cutting speed, torch to work distance are other parameters listed in the chart. 

3. Use Good Consumables

See if your consumables are worn or damaged. They are essential for precision, and any damage could affect the quality and system performance. Therefore, do a visual check and replace it when needed. Use branded alternatives like Mitsubishi spare parts, or Mazak used parts. Always lubricate o-rings while replacing consumables. Don’t over lubricate, as it may affect the system performance. 

Also, make sure that you choose right consumables. Double-check the part numbers on your consumables with the numbers in the manual. 

4. Level your Table and Workpiece

Always level your torch to the workpiece before you start squaring. Because if the metal is bent or wrapped, it would be impossible to square the torch with the workpiece. Or, in the worst case, you may have to accept the poor cut quality. 

5. Hold Right Torch to Work Distance

Ensure that your torch is not close or far away from work, or it would cause rounded cut edges. On top of that, if the torch is too close, the metal splatter would cause severe damage to the torch and nozzle. So, refer to the distance in the manual and adjust accordingly. If your parts are old, adjust them manually as the distance may vary. 

6. Cut at the Right Speed

If the cut speed is low, it may result in broader kerf, dross, and warpage on thin materials. Often, the low-speed dross is collected at the bottom of the cut edge and is easy to remove and flake off. In contrast, high-speed dross causes a thinner bead of molten metal to collect at the bottom of the cut. It is harder to remove and requires grinding. However, you can eliminate it by reducing the cut speed to allow arc time to catch up with the arc torch. 

7. Use Clean and Dry Air

If you’re using air plasma, make sure it’s clean and dry. The same applies to oxygen or multi-gas systems. Use pure and high-quality gases. Make sure that the regulators and gas lines are of appropriate size. Purge-it manually if required. Also, confirm that the purging cycle is completed. Lastly, see if there are any leakages. In case of emergency, contact your gas distributor and get it resolved immediately. 

8. Tune-up your Table

Is the speed of table cutting appropriate? Is the torch secured tightly to the gantry? Is the table vibrating? 

Check all these as often the plasma cutting problem is not with plasma cutters but the poor motion or table issues. So, tune up your table before proceeding with the cut. 

Most importantly, keep implementing these tips. Share your experience with us. If you have any problem with your system or consumables, contact your manufacturer or supplier immediately.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/tips-to-improve-cnc-plasma-quality

5 Laser Cutting Maintenance Tips

If you use a machine vigorously, you know its consequences. It would wear out sooner than expected. The productivity and efficiency would decrease too. 

This principle applies to every machine that we use, including laser cutting machines. If we maintain it properly, we can enhance the longevity of the laser cutters. Though the machines often come with service contracts for a given period, ensuring proper use and brand-specific spare parts like Bystronic parts and Fanuc spare parts is smart.  

However, if we look at the machines only when they malfunction or are broken, it will increase the cost and efforts. Therefore, it is crucial for metal fabricators to maintain their laser machines or it might affect their work and quality. If maintained properly, it can help you save a great deal. Here are the maintenance tips for maintaining your laser machine’s competency and throughput.   

1. Keep the air sources clean

Laser cutting machines use different types of gases like oxygen, nitrogen, or shop air to cut metals. Most of them use shop air as it has the fastest processing speed. It helps cut various metals like stainless steel, aluminum sheets, metal sheets, etc. So, for gases to cut the metal with perfection, ensure that the compressor gas is not impure instead moisture-free. Keep the lines clean and maintain the air pressure and air filtration properly. Do this regularly as the compressor source and lines affect the machine’s performance, productivity, and working life span. 

2. Inspect the parts regularly

The simplest tip to prolong a laser cutting machine’s life is to inspect all the parts on a daily and weekly basis. Check if the pressure of working gas and cutting gas is enough or not. If not, replace it immediately. Check whether the limiting switches of each axis are sensitive. The indicator lights are damaged, whether there are any leakages, etc. See which part needs replacement and replace it with branded parts.

3. Review your chiller performance constantly

Like plasma cutting, fiber laser cutting uses heat to cut the metal. So, you should ensure that the equipment remains cool and doesn’t overheat. Clean the condenser coils, filters, and fans so that they perform well. If there is debris in the filters or fans, they won’t cool the machine. In fact, the discrepancy in the temperature could lead to poor performance. 

Many chillers require additives and chemicals, so maintain them at regular intervals. 

4. Ensure regulated power supply

After one month of continuous power supply, cut off the main supply and check all the electric connections, tighten the terminals, especially the main circuit. 

Along with this, check the elasticity of the slider carbon brush, blow out the toner, and dust on the components using dry compressed air.

5. Inspect the gas delivery

Laser machines use gas to vaporize through the material. The contaminated gases affect the cut and result in poor quality. If you want a smooth cut, make sure that the gas is pure and clean. For this, inspect gases whenever possible. See if they are free of debris. Look if filters are doing their job properly. Replace the gas bottle every time you notice a leak, as it would affect the overall performance. Also, they are a safety hazard to workers working with the device. Hence, whenever you see a leak, turn off the device and then use a soapy connection rag to rub the connection line. Address it as soon as you notice a leak. Any delays will affect your performance, and even your safety will be at risk.

Conclusion

Check your laser cutting machine and parts regularly. If you find any fault or look like a part has failed or is not working properly, replace it immediately. Follow the tips mentioned above for better maintenance. Also, keep your machines clean and track every activity. Lastly, use Bystronic parts or Fanuc spare parts for replacement.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/5-laser-cutting-maintenance-tips

5 Steps to Modernize your Old Press Brake

Just like other press brake owners, you might be wondering what to do with your old press brakes. You might be caught in between selling the old and buying a new press brake. Well, if you’re planning on a new one, I would suggest going for the Amada press brake for sale. But let me tell you that replacing old with new can cost you thousands of dollars. Up of that, you might have to deal with logistics overhead.

A cost-effective solution would be to increase your existing machine’s productivity by retrofitting. In case, if you need to replace parts, you can go for prima spare parts.

While retrofitting, knowing about the type of retrofits and the ones suitable for your machine would be better. It will help you decide whether upgrading the machine is worth it or not.

You can follow these steps to assess the condition of your press brakes.

1. Evaluate the Condition of the Machine

First, identify the condition of hydraulic, mechanical, and electrical components of the machine. While doing so, focus on – RAM, pedestal control, back gauge control, and press brake control. See if your RAM is accurate, consistent, and level on both sides. If they are producing proper results, you can go with a retrofit. Also, check the bending method.

Next, check whether the foot pedestal is working or not. If it is, you can avoid replacement. Also, check if your back gauge needs replacement or reusing would work. Lastly, see if your press brake can work manually, as basic retrofit often works with it.

2. Learn About your Machine

Consider the type of machine you’re working with. If your machine is a mechanical-style press brake, you can add a standalone CNC back gauge system, though ram programmability won’t work.

Rocker-style hydraulic press brake can be retrofitted with a programmable position and control interface. Synchro-style hydraulic brakes often focus on libraries and simulations. So, learn about your machine and then consider retrofitting.

3. Identify the Pain Points

Assess your challenges by asking questions like:

• Which method would be suitable – back gauging or front gauging?
• Are you making frequent changes to the tool? Are you changing die heights often? If so, you can adjust your surface’s height to accommodate the new tool by incorporating the R axis.
• Do you often adjust the angle and depth of the ram manually? If so, adding a ram axis or y-axis would help increase productivity.  
• Do you handle the same parts multiple times and adjust the gauge often? Use the X-axis, Y-axis, R-axis, Z1 axis, and Z2 axis to increase operator productivity. 
• Are operators capable of offline programming? A few retrofits offer offline programming, so operators must be well-versed with programming and provided essential training.  

Evaluate these and jump onto the next step.

4. Determine an Approach

Retrofit companies need to know about your press brake application in order to provide a proper solution. They will ask questions like the length of the press brake. Whether you’re bending little gauge sheet metal or heavy plates. Are single operators enough to support the sheets?

So, determine the approaches you would like to take. For this, keep questioning – How much job storage do I need? Should I add the components’ programmability? Do I need a full tool library? Do I need networking? Will I import DXF, AutoCAD, SolidWorks?

Answering these questions will assist you in determining the retrofit approach.

5. Implement Your Solution

If your press brake is working properly and still you want to increase your bending process’s productivity, you can go for one of three options.

• Leave the machine and limp it for as long as possible.
• Purchase a new multi-axis press brake. (You can choose Amada press brake for sale.)
• Retrofit the whole machine or some parts. (For spare parts, refer to prima spare parts.)

Lastly, you can take the help of an experienced supplier specializing in metal forming and fabrication machinery. 

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/5-steps-to-modernize-your-old-press-brake

4 Tips to Begin your Fabrication Project

Fabrication projects like railroad tracks, power plant facilities require heavy metal cutting. So, fabricators opt for laser technology as it provides precise, accurate, and clear cuts. Also, it has an unmatched speed compared to other cutting technologies available in the market. 

In addition, what makes laser technology different is its adaptable nature. You can adjust it according to your project requirements – resolution, sharpness, depth, and whatnot. In addition to this, brand parts like Hypertherm PowerMax 45xp fine cut consumables and Hypertherm HPR 130 consumables enhance efficiency.

Here are the other things that help you improve your laser cutting for fabrication projects. 

1. Consider Material Thickness and Type

When you plan your next fabrication project, choose the material type and thickness. Every material has different thicknesses and properties. For instance, a thin metal would burn faster than a thick metal. Moreover, it won’t take lasers long to cut through the thin material. So, make sure to check the type of metal you want to use. 

After all, you’re using laser technology for its quality and speed. And choosing the perfect material or working on finding the optimal thickness of the material can considerably cut laser costs. Imagine you cut a heavy metal, and the laser technology is not compatible with it. It may wear out the consumables. 

Finding it won’t be easy if you have a complex project. However, you must consider it, or you may end up with average results.

2. Simplify the Design Elements

Try to implement minimal designs that would reduce the laser cutting usage or time. Because when you use laser cutting, every action counts. You pay for every movement the laser cutter makes. Be it cutting, engraving, or passing between cuts, your consumables and parts wear out with usage. Also, the less time the laser takes to cut, the less it would cost. 

So, keep your designs simple. Tracing minute details will take up a lot of time rather than large designs. For instance, cutting a straight line will take less time than a circle. 

3. Add Complimentary Services

Having a fabrication company that can help you build a main enclosure part or custom part is beneficial. However, look for a company that also provides services like power coating, spot welding, finishing metals, and other techniques that turn a planned component into a finished project. 

If you’re thinking about contracting low bidders for different parts of the job, then don’t. No matter how cheap the services are, it would add up the logistics of working with different companies. Besides, managing work could be challenging. It may create over-head and even increase costly mistakes.

So, hire a qualified vendor that provides complementary services.

4. Find the Appropriate Partner 

To accomplish projects successfully, you need advanced technology like laser cutting. But for quality products, having a skilled vendor is crucial. Here are the questions you must ask:

• Does it have technical capabilities?

Fabrication and laser cutting processes need accuracy, detailed inspections. So, make sure the team can conduct tests and offer feedback.

• Is it easy to work with a particular company? 

To finish projects on time, you need a company that will provide better services and speeds up production. It can be sending designs electronically or communicating on time. 

• Does the company have a stellar record? 

Look for a company that has a record of quality services and on-time delivery. A reputed company can help you manage your supply chains effectively. So, while partnering, check their clients’ testimonials, reviews, ratings, and work portfolio. 

Overall, these three questions will give you an impression of the company you plan to partner with.

Conclusion

Follow these four tips. It will help you get the best of laser cutting for your fabrication project. Also, for consumables prefer Hypertherm PowerMax 45xp fine cut consumables and Hypertherm HPR 130 consumables.

Source: https://altparts.mystrikingly.com/blog/4-tips-to-begin-your-fabrication-project

4 Tips to Maximize your Laser Engraving Production

The good thing about laser cutting and engraving is the speed at which they can etch a pattern or carve even an intrinsic design. However, that’s not enough to boost production. Laser operators often need to look for ways to maximize their productivity. Are you, too, looking for ways to use lasers efficiently?

If so, use Trumpf Parts and Bystronic Spare Parts for laser consumables. They are durable and provide better quality than other brands. 

The other tips that ensure using laser machine to its highest potential are:

1. Engrave Multiple Items in One Go

If you want to boost your production, engrave multiple products in one. It reduces the processing time, efforts, and even cost to a certain extent. For instance, you have to engrave plaques or courses with similar designs. So, there you can print multiple at one instead of designing one at a time. It will help you save your time by 37 percent, says a study. 

However, the number of items you can design depends on your graphic table size. Therefore, make sure that your paper size of the graphic design program meets the highest table size. By doing so, you can print maximum items at once. You can use a jig to space the items so that they don’t mix up while engraving. 

2. Adjust Resolution

Image resolution is important in engraving. The higher the resolution, the better would be the image. But higher the DPI, the more time it would take to engrave. DPI refers to dots per inch, and higher DPI means the engraving dots will be closer. It would result in a higher detailed image. However, it would take more time. 

If you want to engrave in a shorter time, you can go for a low-resolution image. It would save your time by around 33%. You can also offset your resolution with dithering patterns. Dithering patterns are visual dot patterns that you can see in lower DPI. Therefore, to achieve target results adjust resolution and DPI with dithering patterns. You can engrave your design in less time. 

3. Use Color Mapping

Color mapping further helps save time. Let’s say your design consists of three columns with 30 names in each. The laser machine would consider it as a whole instead of separate columns. It would pass through the white space and engrave the names in one color. 

So, to avoid this, you can use color mapping. It would enable you to skip the white spaces and assign different colors to columns, along with engraving order. With this process, your laser would consider columns as different and engrave accordingly. It would travel through the white space only when it has to switch to the next column. The color mapping approach can save you 47% more than others. 

4. Pre-Engrave Items

Customization is popular. Many businesses are adopting it to enhance the customer experience. But for your laser engraving business, it can be inefficient. If you have to engrave the same designs repetitively, it can increase the production time, resulting in inefficiency. However, you can curb it by pre-engraving the inventory before single orders come in. For example, you can pre-design a batch of keychains or cutting boards. When an order comes in, you can add a custom quote or saying according to customers and pass it on. With a little change, you can avoid bottlenecks in day-to-day orders. Also, the small change would take less time than engraving the entire design.

What’s More?

Use center engraving to set custom jobs on items. Using a job manager to streamline the laser workflow is also a great idea to boost productivity. In addition to these, make sure to add high-quality branded parts like Trumpf parts and Bystronic spare parts. After all, maintaining consumables is also a trick to increase laser efficiency.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/4-tips-to-maximize-your-laser-engraving-production

How Laser Cutting Benefits your Business

To get a cut above average, you must first know its detailing. Whether the laser cutting machine is suitable for your product or not. Only when you know the right time to use the latest technology and equipment can improve your product/service quality.

For that, you need to learn about different laser cutting machines, which brand spare parts you should use (like Mazak used parts or Fanuc parts), and so on. 

The most important thing you need to identify is the advantage this technology provides.

Let's see what they are:

1. Versatility

What's the first thing you notice about cutting tools?

It's usually how you can use them from an economy, mass production,, and components perspective. 

Talking about laser cutting, it's highly versatile. Not more people appreciate it, but it's a fact. It's a cost-effective solution for projects that require precision and intricacy.

It's a go-to solution for all metal cutting work.  

Be it aluminum, stainless steel, or titanium, laser cutting can perfectly finish different sizes. You can also apply them to cut zinc and iron.

No matter how hard the material is, it can provide high-quality results. 

2. Reliability

Manual tools and cutting methods rely on well-maintained equipment. They use the sharp cutting blade, but the blade can become blunt, slow, or smooth as the process continues. This may affect the result. There might be variance in edges, or the cutting may not be exact. 

The variances can be minute, naked to the human eye. However, they can make a significant change, mainly if the components are for robotics or automation lines. 

Laser cutting ensures 100% consistency. It ensures that there won't be a difference or distortion of even 0.1mm. 

You can rely on it because it doesn't rely on sharpened blades or oiled mechanisms. Also, there are no maintenance issues. You can directly replace the parts with branded ones, like Fanuc parts.

3. Accuracy

It's another advantage of using laser cutting technology. 

Manual tools rely on varying degrees based on the dexterity of the operator. Even a skilled one would make marginal errors such as a hairline scratch. 

Laser cutting uses digital technology. It's not prone to variations; instead, it offers a high degree of accuracy. 

For example, you want to cut material to create grooves without passing the blade all through the material. The ratio between engraving and the material edge could be fine. For manual tools, it might not be easy. But laser cutting can make that cut with attuned dimensions. 

With laser cutting technology, you can cut minus plus 0.1mm, accurately.

4. Waste and Time Management

Unlike other cutting methods and tools, laser cutting offers a safe environment and reduced waste management.

The goal of this technology is to get results with minimum waste. It means you can get your components or products ready with fewer errors. It also means that you can get more done in less time. As there's no waste, the time spent on clearing the surface is reduced. Next, you can acquire the results in one or two go. 

It's not like the manual tools. You need to move your item to different machines and position them in different angles and directions to get desired results. 

Laser cutting streamlines the process and makes it smooth. Besides, reduced waste management can further help you save costs.

5. Speed

And the primary advantage is it's fast. 

Not only for mass production. If you want to cut a bespoke item, you can take the laser cutting machine, program it, and within minutes, you can operate.

Even if you have a large consignment, you can get it done on time. Laser cutting can cut through the time you would otherwise require to set up a project or a machine. 

Time is also not a challenge. You can use laser cutting technology 24*7. 

Also, you can take repeat orders and fulfill them without re-setting up or adjusting the parameters.

That's how laser cutting technology is.

There are a lot of advantages to it. If you don't go for it today, you may regret it later.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-laser-cutting-benefits-your-business