This article presents all the information you need to know about Marking Machinery.
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Marking machinery is industrial equipment designed to create texts, graphics, labels, and codes on parts and products. Various types of marking machines employ different mechanisms to alter material properties and produce the desired mark. Common mechanisms include stamping, engraving, inking, and etching.
Marking is carried out to provide identification, traceability, and decoration to products or parts, making them easily recognizable by individuals and machines such as scanners, barcode readers, and 2D code readers. This robust process has significantly enhanced the entire supply chain as well as the marketing and advertising of numerous products.
The following chapters will describe common marking methods, including their machinery, operating principles, and applications. The choice of marking method for a particular application depends on the material's physical and chemical properties, return on investment, and the product's value.
The dot peen marking machine uses a marking pin (or peen) made of rigid material, such as carbide, to engrave a series of small dots closely spaced to one another to form straight or curved lines. The engraving by the marking pin induces low stress in the material. The resulting mark is readable, permanent, and has a deep impression on the substrate.
Dot peen marking machines utilize a coordinate system to precisely place dots. The marking pin, which is attached to the marking head, is driven by either a pneumatic or electromechanical system. Parameters such as pin clearance, dot spacing, and pressure can be adjusted to control the contrast and depth of the markings.
Dot peen marking is a fast, accurate, and reliable method for marking metals. This technique can produce logos, text, and 2D codes on a wide range of materials, regardless of size or orientation. Dot peen marking machines require minimal maintenance, as the marking heads and pins have a long service life.
Scribe marking machines employ a stylus with a hardened tip, often made of carbide or diamond, to create marks. The stylus tip lightly punctures the material and is dragged along its surface to form lines or curves. This method produces clear, continuous, and deep impressions that are permanent. Scribe marking is sometimes referred to as "drop and drag" or "scratch" marking.
Compared to dot peen marking machines, scribe marking machines operate more quietly. Dot peen machines generate noise and vibrations due to the repeated striking of the pin, while scribe marking produces less sound because it does not involve repeated impacts. Additionally, scribe marking provides higher resolution due to its ability to create smooth, continuous lines and curves.
The operation of scribe marking machines is guided by a coordinate system that directs the stylus's path. This allows the stylus to be adjusted for marking components with various profiles, including concave, angled, rounded, and irregular shapes.
Scribe marking machines are designed to be mechanically durable and require minimal upkeep. They are commonly used in industries such as transportation, construction, agriculture, and automotive for marking metal parts.
Die marking is one of the most straightforward marking techniques, involving the use of a marking die. This die, which may be either a stroking or rolling type, features a raised, engraved surface that matches the desired pattern. The process can be carried out using either ink-based methods or high-pressure techniques.
In this marking process, inks composed of dyes or pigments are utilized to imprint patterns onto the substrate. Ink is applied to a marking die, which then transfers the ink to the substrate's surface upon contact. The die tip is typically made of rubber. The effectiveness of the marking depends on factors such as the ink's compatibility with the substrate, the volume of ink applied, the drying time, and the die's contact with the substrate.
Ink-based marking is well-suited for brittle substrates like glass and ceramics because it does not apply stress to the material.
Examples of devices that use ink-based die marking include:
These marking devices feature a pneumatically or electronically operated marking head that applies ink through a stroking mechanism. They are frequently utilized in traceability systems across manufacturing and automotive sectors. These devices can print various details like expiration dates, product codes, prices, and labels directly onto products. They can be integrated with production lines, or used as portable or hand-held units.
These marking machines use a flexible silicone rubber pad to transfer a pattern onto the substrate's surface. The ink is applied by gently covering the substrate, which is held steady during the process. This technique is well-suited for applying ink markings in two-dimensional patterns onto three-dimensional surfaces, regardless of their shape or size.
Hot stamping involves transferring ink from a carrier foil to the substrate using a heated die. This technique creates a glossy, reflective mark, making it ideal for decorative text and embellishments.
A die or punch imprints a substrate by applying sufficient pressure to create an indentation on its surface. The die features the pattern to be transferred. Factors affecting the marking quality include the mechanical properties of the substrate and die, as well as the applied pressure. The die must be crafted from a material harder than the substrate to effectively deform its surface.
High-pressure marking equipment encompasses:
These devices produce embossed or debossed effects by applying force to mold and alter the material. The force is exerted through a downward stroke of a punch that has the engraved pattern on its tip.
An embossed mark results in a raised area on the material's surface, while a debossed mark creates a recessed area. Both effects replicate the design of the pattern.
These devices feature a cylindrical die with engravings on its side. As the cylindrical die rolls over the substrate, which is typically in sheet form, it applies pressure to imprint the pattern onto the material.
Thermal inkjet printing is utilized for applying text, graphics, and images onto continuous sheets of materials like paper and plastic. This method involves printers with numerous nozzles that eject ink onto the substrate. Ink is heated by elements situated near the nozzle walls, creating vapor that forms bubbles. These bubbles then burst, expelling the ink through the nozzle tip.
The resolution of inkjet printers is often indicated by the dots per inch (DPI) rating; a higher DPI signifies a greater number of dots per inch and thus better print quality.
Thermal inkjet printers are valued for their affordability and portability. They excel in producing a wide range of colors and gradients that other marking methods may not achieve. However, the printed images are generally less durable and can be susceptible to smudging, staining, and deterioration when exposed to moisture, heat, or frequent handling.
Using stains or ink to mark parts provides a straightforward method to distinguish between similar components, verify a pass/fail status, or confirm the completion of specific processes. Marking during assembly serves various purposes, including identifying approved parts and tracking the machinery used in their production.
In some instances, parts are marked with invisible stains detectable only under ultraviolet (UV) light. This technique helps to identify any tampering with the part.
There are three main types of marking systems: handheld markers, contact marking systems, and non-contact spray marking systems. Handheld markers are the most basic of these, typically used for tasks such as indicating the completion of radiator filling or fluid injection into systems.
Contact marking systems utilize ink or stain stored in a reservoir. When a component is positioned for a process or test, an actuator triggers a dauber to apply a mark on the part, signaling its status upon completion of the process or test.
Non-contact marking systems utilize a spray mechanism to apply colored spots, bands, or stripes. The paint or stain is stored in a reservoir and applied under high pressure. The spray valve can be either fixed in place or attached to an actuator that adjusts its position relative to the part being marked. In more advanced setups, the part may be rotated while the non-contact marker applies a continuous band of color.
Marking solutions used for both contact and non-contact methods are known as inks, stains, or paints, and can be either opaque or transparent.
Clear marking stains are more fluid and dry quickly. They're ideal for lighter surfaces or precision tasks. Their chemical makeup ensures they don't settle or separate over time.
Opaque marking stains contain pigments that create more pronounced and darker marks on any surface. They are applied in a thicker layer and require a longer drying time. The viscosity of these stains can be modified to suit the requirements of particular parts or processes.
Electrochemical etching involves applying a stencil pattern to a conductive material through an electrolytic process. This method, among the oldest for permanent markings, is user-friendly and adaptable to various shapes and sizes of the part being marked.
This technique uniquely preserves the metal's structural integrity without introducing stress points, making it the sole method authorized for marking critical aerospace components (FCP).
Electrochemical marking offers high adaptability to different shapes. The stencil's flexibility allows it to conform to various surfaces, enabling the marking of complex geometries without specialized fixtures.
The process includes these steps:
The electrolytic etching process can utilize either alternating current (AC) or direct current (DC), each influencing the metal's surface in distinct ways. Alternating current (AC) does not erode the material but creates a "native oxide" layer, resulting in a mark that contrasts more with the substrate color. In contrast, direct current (DC) removes some of the material, creating an engraved mark that matches the substrate's color more closely.
Both marking methods produce results that are durable and resistant to abrasion, while the underlying material and areas outside the mark remain unaffected.
Electrolyte solutions used in etching can be mildly alkaline or acidic, necessitating neutralization and cleaning to avoid corrosion of the part. However, some companies offer corrosion-resistant electrolytes that do not need neutralization, preventing rust on ferrous metals and alloys.
Electrochemical etching devices are compact and deliver high-quality, precise markings, including alphanumeric characters, logos, and barcodes like QR and data matrix codes. They are effective on a variety of electrically conductive metals, including aluminum, zinc, steel, stainless steel, and titanium.
Laser marking utilizes laser technology to create permanent marks on workpieces. This process involves high-energy laser beams that are directed at the material's surface to imprint a marking pattern.
Laser marking systems are highly automated and operated via software, allowing for precise and rapid marking on a variety of substrates. Since these systems do not require mechanical contact like clamping, they avoid potential material deformation and damage. Additionally, they do not depend on consumables such as ink or electrolytes.
Laser stands for "Light Amplification by Stimulated Emission of Radiation." A laser beam is generated when electrons in the medium are energized by electrical currents or another laser. As these electrons move to a higher energy state and then return to their original state, they emit photons (light particles). These photons stimulate other atoms to release more photons, resulting in a highly amplified light beam.
At one end of the laser tube, a total reflector is placed to ensure photons reflect back and forth through the medium. At the opposite end, a partial reflector allows some photons to escape, creating a powerful laser beam that heats and alters the surface it hits.
Lasers can operate in pulsed or continuous modes. Pulsed lasers emit energy in brief, intense bursts at regular intervals, resulting in very high peak energy. Continuous-wave lasers, on the other hand, provide a steady, lower energy output throughout their operation.
The energy from the laser marker causes physical or chemical changes based on the substrate type and laser intensity. Various laser marking methods are available to meet different requirements:
Laser engraving uses intense laser beams to vaporize material, creating a visible cavity that forms the mark. The laser must produce sufficient heat to vaporize the material within milliseconds.
Laser engraving achieves depths between 0.0001 and 0.005 inches, while deep laser engraving exceeds 0.005 inches by applying multiple laser pulses. These marks are durable, abrasion-resistant, and maintain readability even after additional treatments.
This technique works on various materials, including metal, plastic, wood, leather, glass, and ceramic, with less risk of damage or deformation compared to mechanical engraving methods.
In laser etching, the laser beam melts the material, causing it to expand and create a raised mark on the surface. This method is quicker than laser engraving because it requires less energy to melt the material rather than vaporize it, making it a more cost-effective choice.
Laser etching produces high-contrast marks with elevations of up to 80 microns. However, because the mark is raised, it is more susceptible to abrasion. This technique is effective on various materials, including aluminum, anodized aluminum, steel, lead, and magnesium.
Laser annealing uses the heat from the laser beam to induce color changes through oxidation, creating marks with contrasting tones. This method requires less energy compared to laser engraving and etching, and does not remove or disintegrate the material. The marking depth typically ranges from 20 to 30 microns, with different colors appearing based on the marking temperature.
This technique is ideal for materials that need to retain their strength and structural integrity after marking, making it suitable for structural applications and medical instruments. It is commonly used on metals such as steel, stainless steel, and titanium. Laser annealing is particularly advantageous for stainless steel as it preserves the protective chromium oxide layer on its surface.
Laser carbonizing involves using the heat from the laser beam to break the polymeric bonds in the substrate, causing it to darken as hydrogen and oxygen gases are released. This reaction creates a noticeable contrast that defines the mark. This technique is suitable for marking organic materials such as synthetic polymers, plastics, wood, paper, and leather. However, it is less effective on dark-colored substrates, as it only creates a mark that is darker than the material's color, resulting in lower contrast.
Laser foaming melts the polymeric material with a laser beam, causing the release of foam and gas bubbles. This results in a raised, lustrous mark in colors such as white, silver, or tan. The bubbles alter the light refraction properties, giving the mark a distinct sheen. Laser foaming is commonly used for marking protective plastics in electronics, signage, and decorative lettering.
Laser marking machines are classified based on their capabilities and specifications into the following types:
CO2 laser machines generate laser light by passing an electric current through a gas mixture containing CO2 within a chamber. The CO2 serves as the laser medium, emitting infrared waves at a wavelength of 10.64 microns. These machines are versatile, capable of performing various marking operations and cutting materials, and are particularly effective for deep engraving. However, they require more power to operate.
CO2 lasers are best suited for marking non-metallic materials such as wood, acrylic, paper, leather, glass, and ceramics. They are less effective on some metals. Typical applications include marking PVC pipes, electronic components, packaging, building materials, and furniture.
Fiber laser machines generate solid-state lasers by directing an electric current through an optical fiber doped with rare-earth elements. The optical fiber serves as the laser medium, emitting electromagnetic waves with a wavelength of 1.064 microns. This setup provides a much smaller focal distance, enhancing the intensity up to 100 times more than CO2 systems with equivalent power output. As a result, fiber lasers are ideal for working with harder and denser materials such as metals and plastics.
Fiber laser machines are low-maintenance and boast a long service life of up to 100,000 hours. They are effective not only on hard metals but also on surfaces with plating, coating, ABS, epoxy resins, and inks. Currently, they are widely used across various industries for applications like IC chips, jewelry, automotive parts, and electronic components.
Green laser machines operate within the green visible spectrum, emitting a wavelength of 532 nm and a power range of 5 to 10 watts. These lasers generate energy at a lower temperature, reducing heat stress on the substrate. They feature a narrow beam spot, as small as 10 microns, which enhances precision and makes them ideal for fine, detailed marking. They are commonly used for marking sensitive materials like silicon wafers, printed circuit boards, glass, ceramics, and thin plastics. However, they are not suited for deep engraving.
UV laser machines emit long-wavelength UV rays in the range of 10 to 400 nm. These lasers are quickly absorbed by substrates, making them effective for marking highly reflective materials. UV laser marking is ideal for cold marking applications where thermal stress must be avoided, such as with glass and ceramics. They are also used for precise marking on circuit boards, microchips, solar panels, and medical equipment like syringes and cylinders.
The ADP2560 Portable Stamper can create deep, durable marks on various surfaces for long-lasting part and product identification. It features carbide marking pins suitable for surfaces up to 60 HRC. The stamper includes an ergonomic handle, a push-button trigger, and a rubber base with light magnets to stabilize it during use. Additionally, it can be customized with a holding bracket to convert it into a benchtop model.
The Zetalase Duo Dial Index is an efficient high-volume laser marking machine designed for continuous operation. It allows operators to load and unload parts while others are being marked, maximizing throughput and minimizing downtime. The machine features a two-position index table, significantly enhancing its throughput rate. It also includes a high-duty cycle rotary indexer and light curtains for operator safety. The marking process is managed by a programmable focal height controller integrated into the unit's software.
The Scribeliner Quietmark employs a drop-and-drag process to create exceptionally clear characters and markings. Its marking head is adjustable to various heights, can be fixed in place, or used as a separate unit for production. Custom-engineered for diverse marking fields and clamp tooling, Scribeliner Quietmark marking heads are designed for durability and ergonomics, making them suitable for high-production environments.
The REA Jet HR series inkjet printers offer high-resolution coding and marking with clean, environmentally friendly, and solvent-free inks suitable for any surface. These printers are maintenance-free, featuring a new print engine with each cartridge replacement. The REA Jet HR includes a 14.4 cm (5.7 in) full-color graphic display with multilingual graphical user guidance. Input options consist of a number pad, cursor blocks, function keys, and a push-button dial. It is capable of printing on both absorbent and non-absorbent surfaces.
The TruMark Station 3000 is a compact and versatile marking system featuring a removable side transfer flap and an intuitive control system. It is designed to handle medium lot sizes within a 24-inch footprint, creating a compact marking cube ideal for flexible desktop use. The system's efficiency can be enhanced by integrating it with the series 1000, 5000, and 6000. Notably, the TruMark Station 3000 emphasizes user safety and offers optional features such as a rotary axis marking table and an exhaust system for base frame models.
Marking machines come in various forms, offering a broad range of options for selecting the most suitable system for specific operations or processes. Understanding these options is crucial for aligning product and part requirements with the appropriate marking technology.
Portable marking machines are handheld devices that operate without the need for computer programming or air compressors. Equipped with a touch screen and software, these machines offer quick, easy, and efficient marking. They are ideal for marking large products and are available in laser, dot peen, or inkjet configurations.
Among portable marking machines, laser models are the most versatile. They work with various materials, whether soft or hard, and are known for their speed. However, despite being labeled as portable, laser marking machines are less mobile due to their attached control units. They come with different laser types—fiber, CO2, and UV—each with varying output powers and material compatibilities.
Portable inkjet marking machines use nozzles or stamps to apply ink. The nozzle method involves firing ink in a programmed pattern, but these machines have limitations as ink may not adhere to all materials. Careful selection of ink is necessary to avoid chemical reactions with the material's surface.
Dot peen or pin portable marking machines create marks by indenting or puncturing the material's surface. As the pin moves, it traces the programmed pattern, letters, or numbers. Dot peen machines are the slowest and offer lower resolution. The pins wear out quickly and require frequent replacement. They are more portable compared to other types and do not need additional equipment.
Integrated marking machines are available with scribing, dot peen, roll, and laser marking technologies. These machines are designed for seamless integration into production operations, allowing for efficient marking and engraving of products and parts. They offer easy programmability, enabling quick adaptation to various systems. The marking process is fast, accurate, and efficient, providing high speed without compromising quality. Integrated marking machines feature advanced, user-friendly software that enhances their versatility.
These integrated systems can be remotely controlled from an external system, allowing them to mark multiple characters in seconds. They are adaptable and easily configurable, with various sizes available to fit different manufacturing or production environments.
Dot peen marking machines, also known as pin marking, dot peening, or pin stamping machines, use carbide or tungsten carbide pins to mark parts and products quickly and efficiently. This direct contact method is ideal for marking dates, time stamps, serial numbers, logos, barcodes, and identification numbers.
Automated dot peen marking systems provide high-speed, deep, and permanent marks. Their primary advantage is the durability of the markings, which can endure harsh and hostile environments, ensuring that the marks last throughout the product's lifetime. Dot peen machines can apply essential information to tough plastic and metal parts in just seconds.
Laser marking machines utilize a highly focused beam of light to alter the surface of a material, creating precise, high-quality markings with exceptional contrast. The laser beam interacts with the material, changing its properties and appearance for accurate marking.
The laser process begins with stimulated atoms releasing concentrated light, which is directed to the marking area. Laser power is measured in wavelengths, with higher wavelengths producing more power. There are six primary types of laser marking: annealing, carbon migration, foaming, coloration, ablation, and frosting.
Annealing Laser Marking - This process involves applying heat to a metal surface, causing a slow but effective change as carbon moves to the surface. It is used for metals and creates a subtle mark.
Carbon Migration Laser Marking - Also used for metals, this method involves heating the metal to bond with its carbon molecules, quickly bringing carbon properties to the surface for a faster marking process.
Foaming Laser Marking - This technique is used on dark-colored plastics, where the laser creates a molten burn that generates a foaming gas. It is not applicable to metals.
Coloration Laser Marking - By adjusting pulse frequency and width, this method heats specific parts of the material’s surface to produce different colors and shades. It is used for plastics to manipulate polymers and for metals as an oxidation process on both treated and untreated surfaces.
Ablation Laser Marking - This process removes the top layer or coating of a material to create a contrasting white mark. It is suitable for anodized aluminum, black oxides, and painted surfaces.
Frosting Laser Marking - The laser moves rapidly over the surface, creating a white contrast with minimal penetration and a slight texture. This method is used on various metals and can be combined with annealing for enhanced contrast.
Selecting the appropriate laser marking method is essential, as each operates differently and matches specific materials. Laser marking provides durability, longevity, and readability for various applications.
A scribe marking machine employs direct marking technology to create precise and aesthetically pleasing markings quickly and powerfully. The process uses a carbide stylus or diamond tip that scratches the material's surface to form deep grooves and continuous lines. This tip penetrates the substrate, producing a permanent indentation. The machine’s software allows the operator to determine the exact location and position of the markings.
The scribe marking process is noiseless and is particularly effective for deep markings on hardened steel. It is compact, consumable-free, robust, and protected by a removable covering, making it easy to integrate into manufacturing and production operations. Known as drop and drag or scratch marking, it works on a variety of materials, including hardened plastics and metals with a Rockwell hardness of 60.
Benchtop scribe marking machines are ideal for marking flat surfaces and large parts in low to medium production runs. They are preferred for creating continuous lines and fine characters due to their high legibility. Like other marking machines, benchtop scribes come with traceability software and are programmed using various controllers.
Basic manual marking machines are fundamental tools designed to perform various marking techniques, such as stamping, piercing, broaching, and coining. These machines are capable of producing uniformly spaced and aligned letters and numbers with consistent depth. Typically, they operate using a large lever that is pulled down to impact the material surface.
Hot manual marking machines are versatile and can be used on materials like wood, paper, and different fabrics. They feature a lever that controls the hot press mechanism. Unlike their cold counterparts, hot manual marking machines are equipped with a thermostat to regulate the temperature.
Roll marking machines utilize a rolling motion to apply marks on cylindrical surfaces and large flat areas. They offer a cost-effective solution for marking and, like scribe marking machines, operate quietly without causing impact damage to components. The process of changing dies and tooling is straightforward and minimally disruptive to production. Roll marking machines are also adaptable for integration into various production and manufacturing workflows.
These machines can be powered by pneumatic or hydraulic systems. Pneumatic roll marking machines are suitable for marking different steels and aluminum, offering a range of marking pressures, stamping spaces, and table sizes, with pressures up to three tons.
Hydraulic roll marking machines, on the other hand, deliver up to 14 tons of pressure, making them ideal for creating deep marks on hardened metals. Like their pneumatic counterparts, hydraulic roll marking machines are designed for easy integration into manufacturing setups.
Manual roll marking machines are another variation, capable of marking aluminum and mild steel. They come with various heads for marking text, logos, or numbers and allow for adjustable marking depth.
Often, roll marking machines need to be customized to meet specific marking requirements for products or parts. Custom fixtures and stamps are designed to create marks without damaging the material's surface. Interchangeable arbors can be used for marking rings or hollow components.
Part marking plays several roles, which makes it a vital process:
Product identification and labeling serve as crucial communication tools between manufacturers and consumers. They provide key details such as the brand name, the manufacturer, and specific product variations. Part marking helps in distinguishing individual products from one another.
Traceability involves tracking and managing data throughout a product's lifecycle, from raw material receipt to product shipment. This practice is mandatory in industries such as automotive, electronics, medical devices, and food and pharmaceuticals. It benefits everyone in the supply chain, including end consumers.
Essential information like production batches, expiration dates, quality control marks, and serial numbers are clearly displayed on individual parts through text and graphics. Advanced traceability systems often utilize 2D and barcodes.
Marking can serve a decorative role by adding artistic details to products and workpieces, enhancing their visual appeal. This type of marking is commonly used in jewelry and craft items to achieve a more attractive finish.
Marking machinery represents a significant industrial investment, offering robust performance and high profitability. These machines come with advanced automation and programmable features, which help cut labor costs and enhance both marking speed and quality. Often, a single operator can manage the entire system with minimal intervention.
To ensure high-quality markings, manufacturers must thoroughly assess and choose the appropriate machinery for their specific requirements. Each type of marking equipment provides unique marking traits. Choosing the right method for the material guarantees clear, legible markings and allows for precise, repeatable marking of multiple parts.
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