{"id":212624,"date":"2025-12-03T09:30:46","date_gmt":"2025-12-03T08:30:46","guid":{"rendered":"https:\/\/www.lasit.it\/automated-laser-marking-for-cutting-tools-the-towertool-solution-for-high-volume-production\/"},"modified":"2026-03-18T10:07:40","modified_gmt":"2026-03-18T09:07:40","slug":"automated-laser-marking-for-cutting-tools-the-towertool-solution-for-high-volume-production","status":"publish","type":"post","link":"https:\/\/www.lasitlaser.com\/automated-laser-marking-for-cutting-tools-the-towertool-solution-for-high-volume-production\/","title":{"rendered":"Automated Laser Marking for Cutting Tools: The TowerTool Solution for High Volume Production"},"content":{"rendered":"\n

Industrial production of cutting tools requires marking solutions that combine speed, accuracy and operational flexibility. When production volumes are high and the dimensional variety of tools is significant, traditional marking systems show their limits in terms of productivity and ability to handle complexity. <\/p>\n\n\n\n

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. <\/p>\n\n\n\n

The Heart of the System: Integration of Laser and Robotics<\/h2>\n\n\n\n

The system is based on an architecture that integrates a fiber laser with configurable powers from 20 to 200W<\/strong> 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. <\/p>\n\n\n\n

The central positioning of the robot ensures maximum flexibility of movement and optimal reaching of all loading points on pallets. The 90\u00b0-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\u00b0 to 90\u00b0<\/strong>, making it possible to mark on any tool surface while always keeping the laser beam perpendicular to the work surface. <\/p>\n\n\n\n

\"powerclean-con-braccio-robotico-1024x635<\/figure>\n\n\n\n

Production Capacity: Up to 1000 Pieces in Autonomy<\/h2>\n\n\n\n

TowerTool’s productivity represents a qualitative leap from manual marking systems. The system is designed to accommodate up to 4 pallets simultaneously<\/strong>: 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<\/strong>, with the actual capacity varying depending on the size of the tools and the load density on the pallets. <\/p>\n\n\n\n

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. <\/p>\n\n\n\n

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. <\/p>\n\n\n\n

\"marcatura-utensili-laser<\/figure>\n\n\n\n

Mechanical Construction: Welded, Stretched and Milled Steel Structure<\/h2>\n\n\n\n

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

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<\/strong>, a treatment that completely releases internal stresses through controlled cycles of heating and cooling. <\/p>\n\n\n\n

Only after stress relief, in the third stage, is the structure machined mechanically by CNC milling<\/strong> 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. <\/p>\n\n\n\n

\"struttura-acciaio-towertool<\/figure>\n\n\n\n

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. <\/p>\n\n\n\n

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. <\/p>\n\n\n\n

Precision in Mechanical Details<\/h2>\n\n\n\n

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

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. <\/p>\n\n\n\n

All motors are equipped with built-in 2048-pulses-per-revolution encoders<\/strong> 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<\/strong>, ensuring durability and corrosion resistance even in demanding production environments. <\/p>\n\n\n\n

\"struttura-lineare-assi-towertool<\/figure>\n\n\n\n

Integrated Industrial Robotics<\/h2>\n\n\n\n

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. <\/p>\n\n\n\n

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\u00b0 to 90\u00b0.<\/p>\n\n\n\n

\"marcatura-utensili-sistema-towertool-<\/figure>\n\n\n\n

Dimensional Variability Management<\/h2>\n\n\n\n

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<\/strong>, which allows the robot to adapt to tools of different diameters without manual intervention. <\/p>\n\n\n\n

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. <\/p>\n\n\n\n

\"pinza-towertool<\/figure>\n\n\n\n

Multi-Position Marking Flexibility<\/h2>\n\n\n\n

The robot’s ability to orient the tool at variable angles from 0\u00b0 to 90\u00b0 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. <\/p>\n\n\n\n

For applications requiring markings at different heights, the system can be equipped with a fully software-programmable motorized Z-axis<\/strong>, 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. <\/p>\n\n\n\n

\n