The problem of marking on high-temperature components

When a metal component is pulled off the production line at high temperatures, its surface has special characteristics: active oxidation, dimensional changes due to thermal expansion, and a thermal conductivity that affects the interaction with the laser beam. In these contexts, traditional microdot or inkjet marking becomes impractical, while laser marking can be calibrated to work effectively even on hot materials.

The main advantage of laser marking on hot parts lies in the possibility of integrating this step directly into the production flow, eliminating the waiting time for component cooling. This translates into significant savings in cycle time and material handling, which is particularly relevant in high-volume production settings such as automotive foundries.

How laser marking on high-temperature surfaces works

Laser marking on hot components requires a specific technical approach. The process relies on the use of fiber-optic laser sources with appropriate powers, typically in the range of 50W, 100W, 200W, 300W or up to 500W for the most demanding applications. These high powers are needed not so much to “penetrate” the material as to ensure high enough marking speeds that the quality of the result is not compromised.

When the part is hot, its surface tends to oxidize rapidly. This oxide layer can adversely affect the readability of the marked code, especially if it is a Data Matrix Code (DMC) intended for automated traceability systems. For this reason, the marking must be deep enough to ensure high contrast even after any subsequent treatments such as sandblasting or shot peening.

The optimum depth of engraving generally varies between 0.1 and 0.3 millimeters, depending on the material and the type of heat or mechanical treatment envisaged in subsequent steps. Marking too shallow risks being erased, while marking too deep can compromise the structural integrity of the component or lengthen the cycle time excessively.

Laboratory test: laser marking on aluminum at 300°C

To demonstrate the effectiveness of laser marking on high-temperature components, LASIT conducted a series of documented and verifiable laboratory tests. In one of these tests, available in video format, an aluminum component is heated up to 300°C using a blowtorch. The temperature is continuously monitored by thermopile to ensure realistic and repeatable conditions.

During the test, the laser marker engraves a DMC code on the surface of the component maintained at elevated temperature. The result is a perfectly readable code with high contrast and adequate depth that withstands subsequent cooling cycles without significant alteration. This type of test not only validates the technology, but also demonstrates the LASIT laboratory’s ability to simulate real production conditions and develop customized solutions for specific needs.

The test represents a concrete example of how laser marking can be integrated into complex industrial processes, where high temperatures are a constant and not an exception. Although the documented test reaches 300°C, the methodological approach and equipment used demonstrate the LASIT laboratory’s preparedness to conduct tests even at higher temperatures, up to the 600°C required by the most extreme applications.

Technical advantages of marking on hot parts

Integrating laser marking directly into the production line, without waiting for parts to cool, offers several technical and operational advantages. The first is the reduction in overall cycle time: eliminating the waiting phase for cooling can mean savings of several minutes per part, with significant impacts on overall plant productivity.

The second advantage concerns the quality of the marking itself. Marking on a hot surface allows deeper engravings with optimized process parameters, since the material is more responsive to laser energy. This results in codes that are more resistant to subsequent treatments and greater long-term reliability.

An additional aspect to consider is the reduction of part handling. In many cases, parts are moved several times along the production line: from casting to cooling, from marking to quality control. Consolidating these steps reduces the risk of accidental damage, improves traceability, and simplifies internal logistics.

When to choose high-power lasers: from 100W up to 500W

The choice of laser power depends mainly on two factors: the required marking speed and the required engraving depth. In cases where very fast marking is required, such as for lines with high productivity, the use of 100W, 200W, 300W or even 500W lasers becomes almost mandatory. These powers make it possible to significantly reduce the marking time while still maintaining a high quality of the result.

It is important to clarify that the increase in power is not primarily to “burn” more material, but to distribute the energy more efficiently and quickly. A 200W laser, for example, can complete the marking of a DMC in seconds, where a 50W laser would take much longer. This becomes critical in applications such as VIN code marking on automotive chassis or traceability of die-cast components in foundries, where every second saved is multiplied by thousands of parts.

For the most demanding applications, where extreme speeds or particularly deep engravings on large components are required, LASIT also offers solutions with lasers up to 500W. This configuration represents the top of the range and allows even the most challenging production processes to be tackled, guaranteeing very short cycle times without compromising marking quality.

In addition, the high powers allow the use of longer pulses and higher repetition rates, optimizing the ablation process of the material. This results in more uniform markings with better defined edges and less risk of microfractures or localized thermal stress.

Industrial applications: foundry and automotive

The main applications of marking on hot parts are found in the foundry and automotive industries. In foundries, aluminum or light alloy components are extracted from the casting at very high temperatures and must be marked quickly to ensure traceability throughout the production chain. The ability to mark directly on the hot part eliminates a waiting phase that, in high-volume plants, can result in significant production bottlenecks.

In the automotive industry, marking on hot components is mainly required for engine parts, chassis, brake systems and transmission components. In many cases, regulations require the marking of DMC codes complying with the AIM-DPM standard, with readability grades between A and B. Laser marking on hot parts allows these standards to be met without compromising production line speed.

A concrete example is the marking of aluminum engine heads, which come off the casting line at temperatures above 400°C. By integrating a laser marking station immediately after casting, the overall process time can be reduced and component traceability can be improved from the earliest processing stages.

Quality verification and integrated control systems

Marking on hot parts also poses additional challenges in terms of quality control. Verifying the readability of the DMC code must take place under less than ideal conditions, with the part still hot and potentially subject to vibration or movement. For this reason, many production lines integrate advanced vision systems, based on Cognex or Dalsa cameras, that verify marking quality in real time according to the AIM-DPM standard.

These systems make it possible to immediately intercept any anomalies, such as incomplete or low-contrast markings, allowing the part to be rejected or remarked before it continues down the line. Integration of these controls is critical to ensure compliance with the quality specifications required by end customers, particularly in the automotive industry where margins for error are very small.

Conclusion: a practical solution for complex industrial needs

Laser marking on hot parts represents an advanced technical solution that meets real and measurable production needs. The ability to integrate this technology directly into high-temperature production lines makes it possible to reduce cycle times, improve traceability and optimize internal logistics. The use of high-power lasers, with configurations up to 500W, combined with integrated quality control systems, ensures reliable results even under extreme conditions.

Laboratory tests conducted by LASIT show that marking on components up to 300°C is technically feasible and industrializable, with results that meet the most stringent quality standards. For applications requiring even higher temperatures, up to 600°C, customized solutions can be developed that take into account the specific characteristics of the material and the production process.

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The process is based on a seemingly simple but technically sophisticated principle: the laser etches the mold in the negative, creating a controlled cavity in the sand. When molten metal is poured into the mold, it fills this cavity, forming a positive relief on the surface of the finished part. The result is a permanent, legible marking that meets industry standards for traceability.

The technical operation of sand marking

Laser engraving on sand molds requires the use of high-power laser sources, typically between 100W and 500W. In industrial practice, the most common configurations use lasers from 200W and up, which are necessary to ensure adequate engraving depths and cycle times compatible with the production rates of modern foundries.

The choice of laser power depends on several factors: the composition of the sand used, the depth of engraving required, the process speed needed, and the geometric complexity of the marking. Molds made with fine-grained sands and resin binders require different parameters than coarser sands or greens.

Controlling the depth and shape of the characters is critical. Insufficient depth compromises the readability of the code on the finished part, while excessive etching can locally weaken the mold or create defects in the casting. Modern laser systems allow precise adjustment of these parameters, ensuring repeatability and uniformity throughout production.

Advantages over traditional methods

The adoption of laser marking to replace mechanical inserts or manual engraving brings measurable operational and economic benefits. Metal inserts, still used in many foundries, require specific design, dedicated manufacturing and complex logistical management. Each change to the marking involves making new inserts, with costs and time impacting production flexibility.

Laser marking eliminates these limitations. Each mold can be uniquely marked, without the need to change the mold design or manage an insert stock. This feature is particularly advantageous in manufacturing contexts characterized by small batches, high variability or production to order.

From the perspective of maintenance and operating costs, the laser has significant advantages. It does not use consumables, require abrasive media, or generate processing residues that need to be disposed of. Maintenance is limited to periodic cleaning of the optics and verification of process parameters, with much longer intervals than with mechanical or chemical systems.

Inline integration and automation

One of the most relevant aspects of laser marking on sand molds is its compatibility with automated processes. In modern foundries, mold production takes place on continuous lines at high cadence, and the integration of laser marking stations must take place without slowing down the production flow.

LASIT systems designed for this application can be integrated directly into molding lines, operating in sync with other process steps. Marking typically occurs immediately after mold forming and before bracket assembly or loading into the casting department. Sensors and vision systems ensure correct positioning of the mold and verify the outcome of marking in real time.

Full process automation eliminates manual intervention, reducing the risk of error and improving traceability. Each mold can be marked with a unique code linked to the foundry’s management system, allowing it to be accurately traced back to process parameters, material batch and responsible operator.

Accuracy, repeatability and process quality

The quality of laser marking depends on multiple factors that must be carefully controlled. Sand consistency is one of the critical parameters: variations in grain size, moisture content, or compaction affect how the laser interacts with the material.

For this reason, the most advanced systems incorporate adaptive control algorithms that compensate for any variations in mold characteristics. Distance sensors, cameras and feedback systems help maintain consistent marking quality even in the presence of dimensional tolerances or variability in the forming process.

Repeatability is guaranteed by the very nature of the laser process, which involves no tool wear or mechanical degradation. Once the optimal parameters for a given mold type have been defined, they can be replicated indefinitely with micrometer precision.

Safety and environmental considerations

Laser marking on sand molds does not involve risks related to the use of aggressive chemicals or extensive thermal processes. The interaction between the laser beam and the sand is confined to a small area and does not generate toxic fumes or hazardous emissions, provided the facility is equipped with adequate extraction and filtration systems.

Environmentally, the absence of consumables and processing waste makes the process sustainable and aligned with circular economy principles. No waste is produced that needs to be disposed of separately, and the energy used is concentrated exclusively in the marking phase, with no significant heat loss.

Specific applications and target industries

Laser marking on sand molds finds application primarily in the cast iron and aluminum foundry industry, where traceability of components for automotive, hydraulics, and heavy engineering is required. Typical examples include engine blocks, cylinder heads, structural supports, and transmission components.

In these contexts, marking has not only an identification function, but also meets stringent regulatory requirements. The ability to mark each part with a unique code, readable even after surface treatments and machining, is a key requirement to ensure compliance with industry regulations.

Foundries that adopt laser marking benefit from greater flexibility in job management, being able to respond quickly to requests for customization or changes to traceability codes without significant impacts on setup times or tooling costs.

Conclusions

Laser marking on sand molds has established itself as a mature and reliable technology capable of replacing traditional methods with concrete advantages in terms of flexibility, accuracy and sustainability. Integration into automated lines and the ability to operate at high cadence make this solution particularly suited to the needs of modern foundries, where traceability and quality are essential parameters.

The evolution of laser systems, with increasing powers and increasingly sophisticated controls, continues to expand the application possibilities of this technology, confirming it as one of the most versatile tools for industrial marking in the foundry industry.

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In the dynamic environment of a modern shop floor, laser marking technology has radically transformed the processes of identifying and tracking components. However, navigating through the sea of available options can be disorienting, especially when the goal is to find the system that fits perfectly with the specific needs of one’s manufacturing operation.

Choosing the ideal laser marker is based on a careful evaluation of interconnected factors that will determine the effectiveness of the investment. This guide reviews the key criteria to consider in selecting the system best suited to your specific needs.

The material dictates the technology: which laser for which applications

The first discriminating factor in choosing a laser marker is the type of materials to be processed. Metals, for example, respond excellently to fiber lasers, which with their specific wavelength can effectively penetrate metal surfaces creating durable, high-contrast markings.

For aluminum, a material that is more refractory to marking than steel, fiber lasers with powers from 30W to 50W are generally recommended, combined with relatively short focal lengths that concentrate energy at a precise point. This configuration allows for perfectly readable datamatrix codes (DMCs) even after surface treatments such as sandblasting.

Plastics, on the other hand, present different challenges. Polymer surfaces can react in unpredictable ways to laser radiation, which is why choosing the right wavelength becomes critical. UV lasers excel on materials such as PMMA or ABS, while green light diode lasers (ONDA or Wave system) offer amazing results due to their extremely short but energetic pulse, which allows plastics to be marked without additives while avoiding carbonization or thermal deformation.

In any case, in more than 90 percent of cases, the fiber laser (often in its MOPA version) is the preferred choice for workshops because it can provide excellent versatility and meet the most common demands of the industry, as well as offering excellent price/performance ratio.

The mechanical configuration according to production volumes

The required productivity significantly determines the most suitable mechanical configuration. For a low-volume shop (50-200 parts/day), a Z-axis-only system is often the most economical and effective solution. These systems allow the height of the marking head to be adjusted relative to the part, ensuring proper focus, but require manual repositioning of the part for markings on different areas.

As production volumes increase (200-500 parts/day), two-axis (XZ) systems become preferable. The addition of the X axis allows larger areas or more parts to be marked simultaneously without manual repositioning. This configuration can increase productivity by up to 25 percent over Z-axis-only systems.

For high productions (over 500 pieces/day), more advanced configurations come into play:

• Rotary table systems: They work in masked time, allowing parts to be loaded/unloaded while others are being marked, eliminating downtime.
• Systems with XYZ axes: The addition of the Y axis further expands the work area, allowing entire pallets of components to be marked in a single cycle. A marker such as the CompactMark, equipped with three linear axes, can process pallets containing dozens or hundreds of parts, dramatically reducing the cycle time per component.

Component geometries and special configurations

The shape and geometric characteristics of the components have a major influence on the configuration needed:

• Cylindrical components or those requiring 360° marking: They require theW (rotary)axis, which allows rotation of the part during marking. This solution is ideal for shafts, rings, ferrules or any component requiring markings distributed around the circumference.
• Non-planar or inclined surfaces: Require a 3-axis scanning head, which allows the optimum focus to be maintained at all times by following the three-dimensional profile of the part. This is especially important for components with curved or multi-level surfaces, where a standard head would produce distorted or blurred markings in areas not perpendicular to the laser beam.
• Heavy or bulky components: For these cases, machines with retractable or side-loading doors, which facilitate handling of parts with lifting systems, are suitable.
• Parts with complex and variable surfaces: Benefit from auto-focus systems that automatically adjust the focal distance according to the morphology of the part. This technology, combined with 3D scanning systems, allows marking of irregular surfaces while maintaining consistent marking quality.

Selection criteria based on specific application needs

Accuracy and tolerances

If the application requires a high degree of precision in marking placement (as in the case of small or tight-tolerance components), it is advisable to opt for systems with a steel frame rather than aluminum. Machines with all-steel construction, such as the CompactMark, offer greater rigidity and stability, ensuring repeatability in the hundredths of a millimeter range.

Production flexibility

For workshops that handle frequent production changes, ease of setup becomes a key criterion. Systems equipped with auto-centering cameras dramatically reduce setup times, allowing rapid changeover from one batch to another without complex manual alignment procedures.

Integration into automated lines

For highly automated manufacturing environments, the ability to integrate with handling systems, robots or assembly lines is crucial. In these cases, in addition to the mechanics of the system, they become crucial:

• Communication protocols: Check compatibility with existing control systems (PROFINET, EtherNet/IP, etc.).
• Customizable software: Ability to develop specific interfaces for communication with corporate MES or ERP.
• Integrated vision systems: To check the quality of marking and send feedback to the control system.

Marking of micro-lots with traceability requirements

For workshops that work primarily to order with variable batches but need full traceability, systems with advanced software that allow:

• Automatic generation of serialized codes
• Historization of markings made
• Association between codes and process parameters

A concrete example: selection of a system for a machine shop

Consider the case of a workshop specializing in machining hydraulic components, with these specific requirements:

• Production: 350-400 pieces/day with peaks up to 600
• Components: Aluminum and steel valves with variable geometries
• Requirements: DMC marking for traceability to automotive standards
• Constraints: Need for double-sided marking of components

Analyzing these requirements, the optimal solution identified is a system with XZ axes and rotating head. This configuration allows:

• Marking in masked time (loading/unloading during processing)
• Ability to process multiple parts simultaneously thanks to the X axis
• Automatic head rotation for multi-sided marking without manual repositioning

The implementation of this solution resulted in:

• 40% reduction in cycle time per component
• Elimination of manual positioning errors
• Ability to handle production peaks without additional resources

Complementary elements that influence choice

Vision systems for quality and positioning

The integration of cameras into the laser marking system is not just an accessory, but something that can significantly influence the choice of system itself. A shop that processes components with high dimensional tolerances or reflective surfaces will benefit greatly from vision systems that allow:

• Self-centering of marking with respect to references on the component
• Automatic verification of marking quality according to standards such as AIM-DPM
• Component type recognition for automatic loading of marking program

Management and customization software

Management software capabilities are another important selection criterion. A system with advanced software enables:

• Manage component databases with associated marking parameters
• Automatically import variable data from external systems
• Program complex marking sequences without manual intervention
• Manage differentiated user profiles for operators and programmers

Suction and filtration systems

For applications that generate significant amounts of dust or fumes (such as deep marking on aluminum), the quality of the suction system becomes a determining factor. Inadequate suction can compromise not only the quality of the marking but also the life of the system’s optical components.

Considerations for future developments

In selecting a laser marking system, it is critical to consider not only current needs but also possible future developments in the workshop. A forward-looking choice will evaluate:

• System modularity: Ability to add axes or accessories at a later date
• Software upgrade: Availability of software upgrades to implement new features
• Service and support: Presence of qualified technical service and availability of spare parts

A system that allows incremental evolutions enables investment to be deferred over time, adapting to changing production needs without the need for complete replacements.

Choosing a technology partner

Selecting the ideal laser marker requires a deep understanding not only of the available technologies, but also of the specific current and future production needs of one’s workshop. In this decision path, the supplier’s role ideally becomes that of a technology partner, capable of analyzing processes, proposing tests on real components and suggesting the most suitable configuration.

LASIT accompanies its customers along this path through marking tests on actual components, analysis of production flows, and support in integration with existing systems, ensuring that the final solution is not simply a laser marker, but a system perfectly tailored to the specific needs of each production reality.

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This technology is based on high-power lasers, typically fibre lasers, which allow engravings with varying depths, from a few microns up to several millimetres. The precision of the process, combined with the possibility of accurately controlling the depth of the engraving, makes this technique particularly suitable for applications requiring permanent and resistant material modifications.

Distinctive features of laser engraving on metal include:

• Creation of deep, defined grooves
• Permanent and wear-resistant result
• Possibility of complex, three-dimensional designs
• Precise control of engraving depth
• No mechanical contact with the surface
• Absence of mechanical stress on the material

How does it work?

The process of laser engraving on metal is based on the use of a high-power laser beam that, concentrated at a precise point, vaporises the metal material. The laser beam, typically generated by a fibre laser, is focused on the surface with extreme precision, reaching temperatures above the melting point of the metal. The main difference to simple marking lies in the power and interaction time of the laser with the material:

• The laser progressively removes layers of material
• The depth of the engraving is controlled through multiple passes of the laser
• The system can modulate power and speed to achieve different depths and finishes
• The process generates a three-dimensional cavity that is visible and perceptible to the touch

LASIT and 3D laser engraving

A particularly advanced aspect of laser engraving on metal concerns the processing of three-dimensional surfaces. In this field, the technology must overcome two fundamental limits: the physical one, related to the inclination of the laser beam, and the mechanical one, determined by the Z-dynamic stroke. When the laser beam hits the surface perpendicularly, it generates a circular spot with maximum energy concentration, thus ensuring maximum incisiveness on the material. However, when the angle of incidence deviates from perpendicularity, the spot becomes increasingly elliptical in shape, reducing the energy density and, consequently, the depth of the engraving. In order to overcome these limitations, the most advanced systems use technologies such as ‘3D Wrapping’ combined with ‘Z-Dynamic’, which make it possible to maintain optimum focus on all points of the surface and to achieve geometrically perfect engravings even on complex shapes such as cylindrical, truncated cone or hemispherical surfaces.

LASIT is able to offer state-of-the-art solutions that allow precise, in-focus marking even on cylindrical components or non-planar surfaces.

Easy-check: Laser engraving for wear monitoring

One of the most innovative applications of laser engraving on metal is monitoring the wear of mechanical components. In this field, laser technology allows calibrated engravings with tolerances in the order of a few microns. An emblematic example is the use of picosecond fibre lasers, which, thanks to their extremely short pulse duration (3 picoseconds), enable extremely precise and controlled engravings to be obtained, without creating thermally altered areas or material remelted on the surface. This micrometric precision opens up new scenarios in the field of quality control and predictive maintenance, making it possible to monitor the wear of metal components with a level of accuracy previously impossible to achieve. This is why LASIT developed the Easycheck application, currently used in the automotive sector for brake discs.

The Easy Check is a ‘calibrated’ engraving directly on the braking track of the disc. Depending on the type of brake disc, the Easy Check is engraved with a specific target depth (usually between 50 and 100 µm) and with tolerances in the order of a few microns. It is also possible to carry out several EasyChecks at different distances from the disc hub in order to monitor any unevenness in wear, just as it is possible to engrave at different depths in order to gradually understand the state of wear of the disc.

Laser engraving of cast components: resistance after sandblasting

Laser engraving on metal has a particular place in the automotive and foundry industries. Being deep and therefore highly resistant, engraving is suitable in these sectors where components are continuously subjected to high stress.

LASIT has developed a system whereby engraving is legible even after invasive processes such as sandblasting and shot peening. Thanks to specific parameters that are set, and high-power lasers (such as 100W, 200W and 300W fibre), we can provide turnkey solutions that are ideal for the casting industry, guaranteeing complete traceability of components. 

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With our technology and much research, we have been able to go beyond conventional 2D code protection techniques, ensuring that laser markings on components remain legible despite abrasion caused by shot peening while also maintaining the quality of the engraved code. Thanks to this innovation, die-cast components can maintain complete traceability from mold extraction to integration into the assembly line.

Under normal circumstances, the impact of carbon steel or stainless steel balls on the surface of a component irreversibly erases or ruins codes and alphanumeric characters. However, our innovative laser engraving process effectively solves this problem, ensuring that codes remain clearly legible even after exposure to Shot Peening.

Optimization for Short Production Cycles

To adapt to the tight pace of production cycles, we refined the laser’s parameters and customized its optical components to generate extremely concentrated energy pulses. These specialized pulses enable us to achieve greater depths of marking in a very short time.

Fiber laser with a power of up to 200W has helped many of our customers double the productivity in their factory. And the speed of reading and grading codes in our systems has further sped up this process.

Online Integration

Within the hostile environment of a foundry, characterized by high temperatures, intense vibration, the presence of water vapor, oil and dust, maintenance problems often threaten production.

Unlike other solutions, our lasers can operate with minimal maintenance even in these harsh conditions. We also offer complete turnkey solutions, leveraging our extensive experience in die casting plants to ensure smooth and reliable integration.

Suction

Of paramount importance in this industry are vacuum systems, which ensure not only the durability of the marking system and its maintenance, but also the health of the operator using it.

LASIT provides powerful, state-of-the-art vacuum systems designed specifically for the hostile environment where die castings are produced to ensure system durability and smooth processing.

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Laser marking systems and micro dot-peen marking have a few things in common, but laser marking has many advantages compared to dated micro dot-peen marking. Now, laser marking has replaced the older technology. When it was first launched, some applications could not use it, but now, laser marking can permanently mark or engrave any surface.

One of the primary differences — which is also the most obvious — is the sticker price of these two technologies. Micro dot-peening is economical. However, laser marking has a greater return on investment over the long term. A Fiber laser has an average operating lifetime of 100,000 hours. Additionally, Fiber technology makes lasers much safer to use and practically maintenance-free.

Let’s take a look at the advantages of laser engraving, considering the main features and functions of the two systems.

Function and mark size

Dot-peening works by having a fine point hit the surface to be engraved with sufficient force to leave a mark. Dot-peening is limited in font type, size and dot density in order to preserve readability.

Laser marking can be as small as 15 microns. It can use unique designs and create a more precise indelible mark. 

 

LASIT FlyCAD marking software provides a simple, user-friendly interface for managing fonts, graphics, sizes, and colors. For traceability, a laser can mark 1×1 mm DataMatrix codes.

Types of marks and engravings

Versatility is one of the most critical advantages laser marking has over dot-peening. First of all, a single laser can mark plastic and metal.

Dot-peening has only a few marking options: data matrix codes, letters, or numbers. Other marks are too complex or even impossible, for example, barcode marking.

If you want color options, that is impossible with dot-peening for obvious reasons. However, with modern MOPA lasers, we have made great strides in colored marking on metal.

Materials

As we’ve already mentioned, laser marking can mark any type of metal, plastic, or organic material. Many lasers, like UV, CO2, and green lasers, are used to mark delicate and fragile materials, for example glass, ceramics, paper, or cardboard.

This versatility is vital for industries like Advertising. Laser marking is the ideal solution for a variety of gadgets and parts.

Easy to integrate

Laser marking can be integrated easily on any production line. Its size and shape make it ideal for working in conjunction with a marking station (including mechanical integration in the line) or autonomously in a line.

Low maintenance costs and ease of part replacement are other points in favor of laser marking over dot-peening. The dot-peening tip wears down and needs to be replaced frequently. This is another reason we say that laser marking has a better ROI over the long term, which fully justifies its initial cost.

 

Here is an interesting article about choosing the best laser marker for your application.

Precision and speed

Laser marking systems are precise and provide incredible flexibility in what can be marked, as well as in shapes and colors. The mechanical aspects of dot-peening marking determine the minimum and maximum sizes of the mark. 

 

In addition to moving easily along in an XYZ coordinate system, lasers can cover a large marking area without physically moving, making it much faster. Its spot is so tiny that it guarantees absolute precision for every application, whether it’s logos, graphics, or 2D codes.

Maintenance

Dot-peening tools need to be calibrated frequently. Parts need to be replaced, and a set maintenance schedule is essential (for example, for the stylus tip that constantly impacts the surface). 

 

Laser marking eliminates 90% of maintenance problems, providing greater precision and control. Also, electricity is the only resource it uses, and even the overload is low. Another important aspect is the noise pollution caused by dot-peening systems. 

Laser markers are extremely quiet and efficient. The safety class is the only point that requires attention for a laser system, as discussed in this article.

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Foundries are the basis of production for almost all industrial sectors. 

They supply practically all types of factories that produce metal components, of all sizes and types. Let’s take a closer look at which sectors are involved and where laser marking can be found in this important industry.

Automotive

The foundry is certainly the protagonist of the automotive sector. All structural engine, chassis, transmission and braking system components come from foundries. They are made of ferrous alloys (cast iron and steel).

In addition to ferrous ones, non-ferrous alloy are also cast. In particular, aluminum and magnesium are among these. They are used for the construction of the structural car components (engine, gearboxes, steering columns, wheels), but also for the bodywork. Furthermore, numerous accessories (such as the door handles) are made of zamak (zinc, aluminum, copper and magnesium alloy).

Even the motorcycle sector cannot survive without the use of cast parts, mainly made of non-ferrous metal alloys such as aluminum but also of cast iron, which are widely used to make the “heart” of the motorcycle: engine and frame. The use of aluminum and zamak castings is also widespread for numerous accessory components such as, for example, cycling parts, levers, headlights.

All vehicle components have traceability codes. Out of all industrial sectors, the automotive sector is probably the one that has this issue most at heart. Each component is marked with an identification code. This code contains all the relevant information for the manufacturer: lot, date and time of production, place and factory of origin. This is essential for safeguarding quality and for prompt service in the event of faults. The codes we are talking about are usually two-dimensional; they always are in the Foundry. In most cases, they are DataMatrix, due to the advantages that these codes provide and which we will analyze later.

Modern airplanes use powerful propulsion engines whose main components are made of cast steel alloy produced with lost-wax precision casting technology. 

Other cast steel, aluminum and magnesium alloys are used for important aircraft and helicopter parts.

We have seen thousands of cast components on our streets. By concentrating a little we, can trace the location of these components that, if not tourist attractions, are fundamental for urban safety and practicality. Manholes allow safe access to the electric, gas, water and sewer networks concealed underground. Street lamps illuminate streets, squares and parks and are often decorative elements too. In addition, in any public park, we have sat down on a bench to rest at least once. These are made of cast iron.

Stoves, boilers, bathtubs are indispensable for a cozy home and for relaxing after a long day of work. None of these components would exist without the foundry industry, which, even if indirectly, provides for our domestic well-being.

 

Even many of the appliances in our homes could not be manufactured without using castings, found in stovetops, refrigerators, washing machines and many small appliances that we use every day.

Electricity cannot be supplied without the use of castings, mainly made with steel or cast iron alloys. Whether it comes from renewable sources (water and wind) or from fossil fuels, the systems cannot be built without cast components. 

 

Water (for hydroelectric plants), steam (for thermoelectric plants) or wind (for wind power plants) propulsion is transmitted to power generators through turbine impellers (steel castings) or drive belts (cast iron).

Ecology

The percentage of recycled materials used to replace the virgin raw material has steadily increased in recent years. 

In Italy, particular attention has been paid to this topic and to the ecology of the system. Today, 75% of the materials used by the Italian foundry industry is recycled, for all those equipped with an electric furnace.

Production waste is also reused in the process: 95% of the soil used in the foundry is reused as raw material, replacing sand and soil from mining activities. Finally, 95% of the water used for furnace cooling is recovered and reused. A perfectly circular system, which makes foundries ecological businesses.

Laser marking on cast components

Laser marking now occurs in the casting process before sandblasting and shot peening. Until recently, this was impossible since these highly invasive processes damaged laser marking results and the code was illegible. The most popular traceability codes are DataMatrix. They are two-dimensional codes that have countless advantages over their one-dimensional equivalents, meaning barcodes.

First of all, DataMatrix codes can contain more than 2000 characters of information. For an equivalent yield, barcode dimensions would be too inconvenient for reading and its creation would be uneconomical.

Writing all this information in the DataMatrix means that a single code can trace: the production lot, the location, the date and time of dispatch, the information in the customer database. The type of datmatrix marked is an ECC 200 according to the AIM DPM standard. This is because laser marked codes are referred to as DPM that stands for Direct Part Marking. Laser marking takes place directly on the cast.

Another advantage of the DataMatrix is its error correction capability. It is readable even if 30% damaged. This characteristic on cast components takes on particular importance as we run this risk with the invasive shot peening and sandblasting processes.

The DataMatrix can be very small in size when made with the laser. Another important fact is that the DataMatrix is readable with a contrast of up to 20%. This is fundamental in the foundry world, where invasive processes such as sandblasting and shot peening could damage it.

At LASIT, we have developed a strategy to overcome this problem. Today, after years of Research and Development, we can mark the 2D code directly on the component that has just come out of the mold. This makes it traceable throughout its journey and the code remains legible even after sandblasting.

We will explore this topic and much more in our event dedicated to foundries: LASIT LIVE – Laser Engraving on Casts, which will be held from May 12th to 14th. We will open the doors of our Laser Test Laboratories to the public for the first time to show our discoveries to the public in meetings dedicated to each individual participant.

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Before going into the more detail on modern 2D codes, it is worth mentioning that their predecessors were the alphanumeric serial codes, used for decades due to being very simple and easily read.
The first barcodes were introduced in the 40s and are still used on many retail products. The fact that they can be read automatically reduces checkout times and the risk of errors. Barcodes have been a real revolution for small and large producers throughout the last century.

Despite this, the problem related to the amount of information to be encoded has arisen since the 80s due to the fact that barcodes are only able to contain a limited amount of data. To overcome this problem, two-dimensional codes were introduced to the market and this often removes the need for separate external databases.

The DataMatrix code

The DataMatrix code is a two-dimensional code that usually consists of black and white modules in rectangular or square pattern.
This code can contain a large amount of information despite its very small size: it is able to tell us what material the object is made of, who made it, where it was made, when, from which company and its precise dimensions.

By reading this code on a product, we can find out all the details, avoid counterfeiting and optimise the production process with precise and effective control.
The other great advantage of the DataMatrix code is its versatility, given that it can be applied to any product including: aerospace vehicles, medical instruments, electronic components and items in the automotive sector.

What are the differences between barcodes and DataMatrix codes?

The barcode we’re used to is made up of light and dark lines that represent letters, numbers, or a combination of the two. It is generally accompanied by a numerical code (EAN) and can be found on any product on the market.
Despite being effective for articles and consumer goods, this code is not enough to track and identify a more complex product. 

This is why the DataMatrix code was created, nearly thirty years after the barcode was introduced. It has been deemed the nephew or third generation of the barcode.
The major difference between the two is that the latter is an analogical code, meaning that the information it holds must be a certain size and in perfect condition in order to be read, both in terms of contrast and in the positioning of the elements. 
Unlike the bar code, the DataMatrix code is digital, much easier to read and more difficult to damage due to how small it is (usually between 5 and 10mm).

What are the differences between QRcodes and DataMatrix codes?

The QRcode (abbreviated from Quick Response Code) was developed to allow rapid decoding of its content. As you can see in the image, the QRcode is different from the DataMatrix and the largest graphic space is occupied by geolocation information. A QRcode is able to hold up to 2.335 alphanumeric characters, has a 30% error correction capability and is mainly used for online and commercial applications. The best thing about this code is its ability to handle special characters (such as the Japanese alphabet) and the ability to interface easily with networked resources. The DataMatrix code on the other hand can hold up to 4.296 alphanumeric characters, 33% error correction capability and can enclose a large volume of information in a very small space. 

That’s why it is the ideal solution for database tracking and supply systems for professional use. The high readability also makes DataMatrix codes more suitable for industrial applications in various sectors and satisfies even the most demanding producers.

Another interesting fact about the QRcode is that it is often applied to the packaging of the product, so once the package is discarded, the information is lost.

DM codes are applied directly to the product, to hidden areas, so that any useful information is preserved but the design and aesthetics are not compromised.

Something curious that both of these codes have in common is that they both require a white border, which is called a quiet zone. This guarantees correct reading and interpretation of the data present.
Thus, we can conclude that the advantages of the DataMatrix code are:

How is a DataMatrix code applied to a product?

Once we understand the huge benefits of the DataMatrix code, we then need to understand how it can be applied to our products. 

The best way to do this is undoubtedly laser marking, both because it can be applied to many materials (plastic, metals, and wood), but also because it allows you to create codes using the extreme versatility of ASCII characters and symbols, which can be changed directly from the within the software.
The laser marker even allows you to enter the code at a certain depth, so that it is more durable and to keep track of our product.

The advantages of laser marking with DataMatrix codes

• Automation

A large industrial production process needs to be integrated to save both time and cost. Laser marking systems are designed to be highly dynamic, integrated and configured according to the production chain, and connected to the software.

• Durability

Laser marking is indelible and almost impossible to damage. This is essential where we need to get information about a damaged product or after a long period of time.

• Data dynamism

An automated process allows us to monitor data constantly so that we can access any information required for production or to make necessary changes before the next phase.

• Size

The laser spot is very small, which means it can also mark difficult to reach parts of the product without compromising aesthetics and design.

• Cost reduction

Laser marking is more cost-effective than other traceability systems, given that there are no costs for maintenance or disposal of waste materials.

• Quality

Laser marking guarantees very high precision even with complex geometric details and the material is cleaned at the end of the process to guarantee perfect results.

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