Four ways researchers harness the power of lasers to achieve manufacturing excellence

The use of industrial lasers has become a viable option for many manufacturing processes. It enables workers to simplify steps, improve precision and benefit from the benefits associated with output. Decision makers will get the best results when they consider the specific possibilities of using lasers in manufacturing. Here are some options.

 

Improved cleaning and texturing methods

Many manufacturers use lasers to clean surfaces efficiently and precisely. For example, car manufacturers can quickly discover how time-consuming traditional parts masking methods can be. Related to this task is the fact that techniques such as sandblasting can remove contaminants but carry the risk of surface damage. These are a few reasons why manufacturers are more commonly choosing laser-based cleaning methods.

 

Local laser cleaning allows manufacturers to focus on specific areas, eliminating the need to cover up parts. The use of industrial lasers is also a way to texture the surfaces of parts, for example in preparation for thermal spraying. This method can create repeatable patterns at the micron scale. Manufacturers appreciate how the approach supports productivity and provides predictable results, even when dealing with large pieces.

 

People also use manufacturing lasers to clean parts before and after welding. This allows them to remove contaminants from their respective surfaces. In addition, the laser cleaning method can solve the discoloration problem caused by oxidation and improve the welding quality of some materials.

 

Manufacturers can improve results by using AI tools to analyze weld quality. Some automation software can automatically evaluate laser welds, thereby increasing production. They are attractive possibilities for people who are already familiar with using lasers for cleaning.

Among the many ways workers use lasers for cleaning, the device is often integrated into an existing assembly line, saving space. However, people can also use handheld devices, which gives them more flexibility.

 

Using industrial lasers to purify food

People working in food processing plants must quickly deal with suspected contamination incidents. Otherwise, consumers could get sick, leading to recalls, regulatory scrutiny, lost profits and other adverse consequences. Food producers must also demonstrate that they meet minimum standards of good manufacturing practice. Carbon dioxide lasers in manufacturing environments can help eliminate microbial contamination without damaging the affected consumables.

 

When used at the right intensity, they will slightly raise the temperature of the food without causing noticeable effects. Although some laser decontamination can cause minor surface changes, manufacturers can take various measures, such as using antioxidants, to reduce these effects.

 

Cooking food with a CO2 laser can reduce food-borne pathogens and prevent complications later in life. However, the precise nature of the laser in manufacturing means that people can only process one part of the food at a time, such as the fatty part of a piece of bacon. On the contrary, since people can adjust parameters such as energy levels and exposure time, this purification method provides them with excellent control.

 

Manufacturers can also use CO2 lasers to purify surfaces used for food processing, such as conveyor belts. One of the advantages of this option is that it is well suited for removing biofilms and organics. The efficiency of industrial lasers is a major selling point for large food manufacturing plants, where cleaning by manual methods takes a long time. On a related note, lasers provide repeatable results that are generally beyond what humans can do. Because people often feel tired or distracted, their results are not necessarily consistent.

 

Laser marking of products to support traceability

The manufacturer's interest in the product does not end with the product leaving the factory. Instead, they often wonder what will happen before consumers stop using the goods. There are many potential benefits to such oversight. Careful tracing may reveal that a particular redesigned product may be subject to warranty claims processing within 18 months of its creation. If previous versions of these products can last longer without problems, it indicates that the manufacturer should investigate possible problems with the new design.

 

By adding visible details, manufacturers can more easily verify whether a product is genuine or counterfeit. For real producers, this is a great way to protect their reputation. Even if the fakes come from elsewhere, the impact can still have a negative impact on the companies that produce the real thing. However, after marking using an industrial laser, manufacturers can describe what people should look for to check authenticity.

 

Laser marking is also very suitable for manufacturing because it offers versatility. Someone can use an ultraviolet laser to add the mark without heating, thus protecting the integrity of the component. Lasers can even be marked with detailed schematic markings on the surface to provide important instructions to the user. Printed circuit board manufacturers often choose laser marking because it is resistant to welding.

 

One of the disadvantages of other marking methods is that post-processing methods such as powder coating and heat treatment may erase details or make them unreadable. In contrast, laser marking is very durable and has excellent wear resistance.

 

Strengthen quality control and product development

Manufacturers take various measures to support the quality control of their facilities. Their efforts include staff training, equipment maintenance and a rigorous evaluation process. While the human element is still important to ensure that products meet minimum standards, laser scanners can complement people's efforts.

 

A recent innovation involves ultraviolet lasers and Rayleigh scattering to check gas turbine engines. The measurement results obtained by this method verify that the turbofan components have achieved the necessary thrust. Those involved in the project say it will further develop core engine technology and could provide in-flight measurements of non-CO2 engine emissions.

 

Lasers in manufacturing can also help companies ensure that parts on the production line meet specifications. Some products on the market capture more than a million data points per second, which makes them much faster than people can achieve. Humans play an important role in validating the instructions of laser measurement equipment and flagging any problems that arise.

 

Because many laser-based measurement devices are suitable for products of a wide variety of shapes, colors, and materials, manufacturers can find plenty of potential uses for them. Although measurement is only one aspect of quality control, it is crucial because errors in this area can negatively impact almost every other aspect.

 

Lasers have many uses in manufacturing

These are just some of the many ways people are applying lasers in manufacturing and achieving impressive results. If you are considering using industrial lasers in certain processes, take the time to research the current options on the market and find some within your budget. Then, after investing in at least one solution, provide adequate training to all employees involved so that they can use the laser safely and effectively.

 

The final thing to keep in mind is that the way you use your laser may change depending on the product being produced, the average yield, and the overall goal. Consider choosing at least one method for conducting laser experiments at your facility. After understanding whether the application makes financial sense, you'll have the information you need to consider scaling up your work.

 

Emily Newton is a technology and industry reporter. She is also editor in chief of Revolutionized magazine. She has more than five years of experience covering warehousing, logistics and distribution stories.

 

Source: Laser Network