The answer to these needs comes from an integrated solution that combines fiber laser technology, robotic automation and customized software in a system designed specifically for the cutting tool industry. TowerTool represents a fully automated laser marking station developed to handle tools with lengths ranging from 40 to 370 mm and diameters from 4 to 25 mm, while maintaining high standards of quality and traceability.

The Heart of the System: Integration of Laser and Robotics

The system is based on an architecture that integrates a fiber laser with configurable powers from 20 to 200W with an industrial robotic arm positioned centrally in the work booth. The choice of laser power depends on the specific application: the most common configurations use 30 to 50W sources, which represent the best compromise between marking speed, result quality, and operating costs for most carbide and high-speed steel tools.

The central positioning of the robot ensures maximum flexibility of movement and optimal reaching of all loading points on pallets. The 90°-mounted laser scanning head allows marking along the tool shank or on the tool base, but the true versatility of the system lies in the robot’s ability to orient the tool at variable angles from 0° to 90°, making it possible to mark on any tool surface while always keeping the laser beam perpendicular to the work surface.

Production Capacity: Up to 1000 Pieces in Autonomy

TowerTool’s productivity represents a qualitative leap from manual marking systems. The system is designed to accommodate up to 4 pallets simultaneously: two pallets loaded with tools for marking and two empty pallets for unloading machined parts. This configuration allows for full autonomous marking of up to 1,000 parts per cycle, with the actual capacity varying depending on the size of the tools and the load density on the pallets.

The fully automated cycle eliminates downtime between parts: while the laser is marking one tool, the system is already ready to pick up the next. The combination of fast handling and high-powered lasers enables the processing of hundreds of tools per shift, while maintaining consistent quality of each individual marking.

Once the pallets are loaded, the operator can devote himself to other activities while the machine works in complete autonomy for hours. This configuration keeps production running for extended periods, maximizing plant utilization and freeing up human resources for higher value-added activities.

Mechanical Construction: Welded, Stretched and Milled Steel Structure

TowerTool’s mechanical strength is what really sets the system apart. The all-welded steel structure is the engineering heart of the system, designed and built in-house to ensure rigidity, precision and reliability over time.

The construction process follows a strict three-stage methodology. In the first stage, steel components are welded together to create the load-bearing frame. Welding, if left untreated, introduces internal stresses into the material that could cause deformation over time. For this reason, in the second stage, the welded frame undergoes thermal stress relief, a treatment that completely releases internal stresses through controlled cycles of heating and cooling.

Only after stress relief, in the third stage, is the structure machined mechanically by CNC milling of the reference surfaces. This process ensures tight dimensional tolerances and flatness of the mounting surfaces, which are key to maintaining precision of movement and repeatability of marking operations.

Unlike bolted-assembled aluminum profile frames, the welded steel frame offers much higher torsional and flexural stiffness. This rigidity is critical for absorbing the dynamic stresses generated by the rapid movements of the robot and for maintaining unchanged working conditions even after thousands of operating hours.

The mass of the steel structure also contributes to vibration absorption, providing stability during acceleration and deceleration of the robotic arm. This results in greater positioning accuracy and, consequently, superior marking quality.

Precision in Mechanical Details

In addition to the main frame, all motion components are selected to ensure high-level industrial performance. Bosch Rexroth linear guides and high-precision ball screws ensure smooth and repeatable movements for the motorized Z-axis, if any.

The ballscrews are free of axial backlash and mounted with double bearings on the gear side to provide higher rotational speed and high radial stiffness. This assembly allows them to be twice as fast as standard configurations, increasing the radial stiffness factor from 12.1 to 18.9.

All motors are equipped with built-in 2048-pulses-per-revolution encoders that enable precise position control in real time. Marking begins only when all axes have reached the correct position, avoiding errors due to inaccurate positioning. All fastening components are made of stainless steel, ensuring durability and corrosion resistance even in demanding production environments.

Integrated Industrial Robotics

The system integrates robotic arms from industrial manufacturers such as ABB, selected for reliability, precision and speed of execution. The robot simultaneously handles picking, positioning in front of the laser and manipulating the tool to mark on different surfaces, all with smooth, coordinated movements that minimize cycle times.

The choice of industrial robotics ensures repeatability of movements essential when working with tight marking tolerances, allowing the tool to be precisely oriented for markings on angles ranging from 0° to 90°.

Dimensional Variability Management

One of the main challenges in automated marking of cutting tools is the considerable dimensional variability between different products. TowerTool addresses this issue through a gripper system with automatically interchangeable fingers, which allows the robot to adapt to tools of different diameters without manual intervention.

The gripper grabs tools by the shank, preventing any contact with the cutting edge and preventing damage to the active part of the tool. Automatic finger changing allows mixed batches to be handled without interruption, maintaining high productivity even with frequent product changes.

Multi-Position Marking Flexibility

The robot’s ability to orient the tool at variable angles from 0° to 90° provides complete versatility in the application of markings. The system can mark vertically along the shank, horizontally on the base, or at any intermediate angle required by the application. Robotic handling ensures that the tool is always positioned at the correct focal distance from the laser, regardless of geometry or size.

For applications requiring markings at different heights, the system can be equipped with a fully software-programmable motorized Z-axis, which coordinates its movements with the robotic arm for multi-level markings without the need for manual repositioning. The Z-axis is constructed with a double profile to maximize rigidity and uses a trapezoidal screw that prevents dropping if the motor loses torque.

Integrated Quality Verification

The presence of the marking is automatically verified through a TTL (Through The Lens) vision system integrated directly into the laser scanning head. This solution eliminates the need for additional robot or laser head movements for inspection, reducing the overall cycle time.

The system uses OCR technology to recognize a portion of the marking and confirm the presence of the code. Specific lighting designed to prevent reflections on the metal surface of tools ensures optimal conditions for recognition, increasing the reliability of quality control and contributing to overall productivity by eliminating manual inspection time.

Customized Software for Industry 4.0

The entire system is controlled through a software interface that can be customized according to specific customer requirements. The software manages simultaneously the 4 pallets loaded on the machine, displaying for each one the essential information: product type, pallet identifier, total number of pieces to be marked, possibility to select specific rows and columns in case of partial marking.

The application can receive markup data from different types of connectors (SQL, Oracle, XML, CSV, text files) and use them to automatically populate layouts containing dynamic fields. A local SQL Express database records a complete log of operations, accessible by the client via ODBC connection or simple Excel spreadsheets.

The system is prepared tointerface with enterpriseIT systems such as ERP or MES through standard communication protocols (including OPC-UA), enabling full integration into the Industry 4.0 environment. Comprehensive monitoring of I/O and machine functions allows maintenance personnel to access all critical information in case of anomalies, reducing downtime and maintaining high productivity.

Production Flow Automation

The operating cycle is designed to minimize downtime and maximize system autonomy. The operator loads up to four pallets onto a manual sliding table that pulls completely out of the cab to facilitate loading and unloading: two complete pallets of tools to be marked and two empty pallets intended to receive machined tools.

Once the cycle is started, the pneumatic door closes automatically and the system starts working completely autonomously. The robotic arm picks up each tool from the loading pallet, positions it in front of the laser head at the required angle while maintaining the correct focal distance, performs marking at the programmed positions, verifies the quality via vision system, and finally deposits the marked tool into the unloading pallet following predetermined trajectories.

Each pick position in the loading pallet corresponds to a specific storage position in the unloading pallet, ensuring complete traceability of the process. The system is designed to use the customer’s existing pallets, simplifying integration into the existing production line without the need for additional investment in dedicated equipment.

Integration into Existing Production

The ability to use the customer’s existing pallets is a significant advantage for integrating the TowerTool system into already operating production lines. The work table is customized to accommodate pallets of different sizes, avoiding additional investment in dedicated equipment and simplifying material logistics.

The preinstalled remote support system (TeamViewer or other software according to customer preference) enables rapid technical support interventions, reducing downtime and ensuring business continuity.

Aspiration and Work Environment Management

A suction system with a three-stage filter built into the base of the machine ensures a clean working environment. The side channel pump with die-cast aluminum construction ensures high airflow, while the filtration system combines HEPA H14 elements and activated carbon to remove microparticles and odors. Full integration of the vacuum system into the machine base eliminates the need for bulky external equipment, optimizing production space.

Safety and Regulatory Compliance TowerTool is a Class I laser system designed according to safety category PL. The front pneumatic door is equipped with a sensitive edge that detects obstacles during closing, while lighted safety barriers provide operator protection. The Siemens S1200 controller handles all safety functions, with specific relays and dual contactor circuits.

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Handling of heavy and bulky parts

Those who manufacture press tools know that handling parts up to a meter long and weighing tens of kilograms is not trivial. Loading and unloading can slow production and increase the risk of positioning errors. The FlyRun integrates a roller conveyor system both inside and outside the marking chamber, available in manual or motorized versions depending on production needs, which allows tools to be transported in a smooth and controlled manner.

This approach offers real advantages: the operator can load the part from the outside, advance it to the work area and, once marking is complete, unload the component without physical effort. The motorized configuration is also compatible with mechanical arms, collaborative robots or lifting systems, allowing integration into semi-automatic or fully automated lines.

Automatic positioning system

One of the most common critical issues in tool marking is ensuring that each part is positioned exactly the same. Even slight variations can compromise the readability of the code or the aesthetic quality of the logo. For this reason, the FlyRun is equipped with a pneumatic positioning system that automatically brings the tool to a stop along the X and Y axes.

This mechanism eliminates the uncertainties associated with manual positioning and drastically reduces setup time. The operator no longer has to measure, align or verify: the part is automatically centered in the correct position, ensuring millimeter repeatability even on batches of hundreds of parts.

XYZ axes for multiple markings

Press tools rarely require a single marking. Often it is necessary to engrave identification codes, logos or technical specifications at multiple locations on the same component. With a conventional machine, this would involve multiple manual repositionings, resulting in wasted time and risk of errors.

The FlyRun solves this problem with its fully integrated XYZ motorized axes. The laser head moves automatically along all three dimensions, allowing extensive surfaces (up to 500×300 mm) to be marked without having to move the part manually. FlyCAD software independently manages the marking sequence, dividing the drawing into sections and coordinating axis movements to cover the entire required area.

In some cases, lateral or inclined surfaces may also need to be marked. For these applications, the FlyRun offers the option of integrating the 90-degree oriented scanning head, further expanding application possibilities without the need for complex part rotation systems.

MOPA laser for black and white markings

In the field of press tooling, more than 90 percent of requests are for black or white markings on steel. This type of finishing requires very precise control of the energy released by the laser, which is only possible with variable pulse sources (MOPAs). Unlike standard fiber lasers, MOPAs allow the pulse duration to be modulated to achieve surface annealing effects without ablation of the material.

The result is high-contrast, aesthetically professional and durable marking. For applications requiring high productivity, the FlyRun can mount 50W or 100W lasers, which significantly reduce cycle times while maintaining consistent quality. The use of wide focal lengths (FFL330 or FFL420) also allows energy to be distributed more evenly, improving the annealing effect and reducing the risk of localized thermal stress.

Steel construction for stability and durability

Mechanical strength is a key requirement for those working with heavy components and intensive production cycles. The FlyRun is made with a welded, stretched and milled steel structure, which ensures dimensional stability over time and minimizes vibration during axis movements.

This attention to construction translates into practical advantages: greater positioning accuracy, less wear on mechanical components and reduced maintenance requirements. The machine is designed to operate in even harsh industrial environments, maintaining consistent performance even after thousands of hours of operation.

Applications even beyond pressing

Although the FlyRun was designed with the press tool sector in mind, its technical features make it suitable for other industrial applications as well. Large mechanical components, molds, light carpentry parts or tools for other machine tools can benefit from the same approach: facilitated loading, automatic positioning and multi-point marking.

The flexibility of FlyCAD software makes it easy to handle even variable batch production, with the ability to recall different marking programs in seconds. This drastically reduces downtime associated with production changeovers, a critical factor for those working on order or with high code variety.

Benefits for the production flow

Integrating a FlyRun means rethinking the marking process not as an ancillary step, but as an integral part of the production cycle. Reduced setup time, automated positioning and the ability to mark multiple areas without manual intervention result in measurable increases in hourly productivity.

For companies that work on large volumes or want to offer more value-added services to their customers, laser marking with dedicated systems such as FlyRun is an almost obligatory step. Permanent traceability, aesthetic professionalism and speed of execution are elements that today’s market increasingly demands, and that only specialized technologies can guarantee.

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A compact and functional structure

The TowerMark-X features a structure that integrates all components-from the PC to the laser system, from suction to controls-into the lower compartment of the machine, effectively protecting them from dust and processing debris. Despite its small size, the system offers a large working area of 750×475 mm. X-axis travel of 500mm, combined with several available optics, allows for variable marking areas: 500x100mm with FFL160 optics, 570x170mm with FFL254 and up to 630x230mm with FFL330. Z-axis travel of up to 400 mm also enables the handling of components of considerable height.

The right laser source

In most applications, the TowerMark-X is equipped with a 20 or 30W fiber laser, powers that guarantee excellent performance on all metals and technical plastics typically found on the shop floor. Higher powers are also available for special applications, but experience shows that these configurations are more than sufficient for typical industry requirements. The system allows markings of all kinds: company logos, DataMatrix codes, QR codes, bar codes, serial numbering and text of all kinds.

FlyCAD software: simplicity and effectiveness

The system uses FlyCAD, proprietary software developed entirely by LASIT. The interface, based on CAD standards, is immediately familiar to those working on the shop floor. The software offers:

• Direct import of the most common formats (DXF, DWG, PDF, EPS, AI)
• Advanced management of marking parameters for different materials
• Library of predefined parameters for common applications
• Automated management of series and coding
• Real-time marking preview

Complete ownership of the software allows LASIT to quickly implement new features based on user needs.

Configurations for every need

The TowerMark-X can be customized with different options for specific applications:

• W axis with spindle for marking cylindrical components at 360°.
• 3D head for non-planar surfaces, which automatically maintains the correct focal distance and angle of incidence of the laser beam
• Vision system for automatic centering and quality verification of markings
• Upgrade to MOPA laser for applications requiring special aesthetic quality or markings on specific materials
• Enhanced vacuum systems for intensive applications
• Customized software interfaces for integration with management systems

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When we speak of efficiency and flexibility in the world of Laser Marking and its infinite applications, we certainly place fiber lasers in first place. In today’s market, these are by far the most used in companies that use this technology.

What is the fibre optic laser?

The fibre laser represents one of the most advanced and widely used technologies in the field of industrial laser marking. This particular type of laser uses an optical fibre doped with ytterbium as the active medium to generate the laser beam. Unlike conventional lasers, the fibre laser is characterised by its outstanding energy efficiency and the superior quality of the light beam produced. In the specific context of laser marking, this technology has revolutionised the industry with its millimetre accuracy and ability to work on a wide range of materials, such as metals and plastics. The fibre laser marking system is characterised by its compactness, minimal maintenance required and long service life, which can exceed 100,000 working hours. These features, coupled with the high process speed and the ability to produce high-quality permanent markings, have made the fibre laser the preferred choice for numerous industrial applications, from product traceability to component customisation.

How does it work?

The fibre laser belongs to the solid-state laser family and is distinguished by its innovative operating principle. Unlike conventional lasers, the laser beam generation process starts with a low-power ‘seed’ laser, whose beam is progressively amplified through a series of ytterbium-doped optical fibres. Amplification occurs thanks to pumping diodes, which supply energy to the fibre through direct coupling, eliminating the inefficiencies caused by air gaps present in conventional systems.

The structure of the fibre laser is characterised by its integrated ‘all-fibre’ architecture, where all critical components – the active fibre, fibre combiners and pump laser diodes – are directly connected to the main fibre via permanent splices. This configuration represents a significant advantage over diode or lamp lasers, where the components are separate and mounted on a platform with mechanical alignments that can deteriorate over time.

The technical performance of the fibre laser is remarkable: it operates at a wavelength of 1064 µm and, thanks to its extremely small focal diameter, achieves an intensity 100 times higher than CO2 lasers of the same power. The electro-optical conversion efficiency exceeds 30%, an exceptional value that translates into low energy consumption in the order of a few hundred watts. The cooling system, simpler than conventional lasers, contributes to the overall reliability of the device, guaranteeing an operating life of more than 100,000 hours.

The laser beam generation process can be schematised in three main steps:

• Initial generation: the seed laser produces a low-power base beam
• Amplification: the signal passes through ytterbium-doped fibres, where pumping diodes provide the energy required for amplification
• Emission: the laser beam, now amplified and highly focused, is emitted with optimal characteristics for marking

What does LASIT offer?

LASIT offers a wide range of fibre lasers, differing in performance and power. From the traditional fibre laser, which is suitable for marking all metals and most plastics, we move on to the MOPA and Picosecond variants.

1. The MOPA laser is distinguished by its ability to control pulse duration. This favours the marking of plastic components while avoiding burning and smearing. On metal, the main advantage is the possibility of marking in colour.
2. The Picosecond laser has three times the speed of the conventional laser. It is distinguished by its black, impalpable, reflection-free markings, which are particularly used in the medical industry. It is also capable of marking on glass, where many lasers fail.

The fibre lasers supplied by LASIT can be integrated into various marking systems, either stand-alone or in-line.

Application fields of the fibre laser

The fibre laser marks all metals and most plastics. If we take into account its MOPA and Picosecond variants, the range of possible applications increases even further to cover most requirements. Consequently, we can say that the fibre laser is suitable for:

Automotive

We mark metal, cast and die-cast components with indelible DMC codes, carrying out marking durability tests to ensure traceability. For automotive lighting plastics, LASIT produces systems for cutting sprues and aesthetic marking of interiors and headlights.

Household appliances

We brand oven panels and small appliance components such as buttons and knobs.

Electronics

We brand all electronic components, such as circuit breakers, residual current devices and relays.

Hydraulics

We directly mark small valves and pumps, and metal plates to be affixed to components that cannot be placed on the machine or in-line.

Promotional

We are experts in the automatic marking of metal and plastic gadgets, from key rings to pens, mugs and water bottles, for which we have developed specific systems.

Faucets

We mark the surface of the faucet, guaranteeing the durability of the marking and thus the resistance of the manufacturer’s brand even on surfaces exposed to wear and tear.

Medical

We mark plastic and metal instruments and prostheses, in particular the latter with Picosecond technology that guarantees indelible, black, impalpable and non-reflecting marks.

Tools

We brand all tools, from cutters to blades, guaranteeing the permanence of the engraving over time.

Moulding plastics

With the fibre laser we can mark all components from moulding machines, regardless of shape and colour.

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