Solutions to Common Laser Marking Problems: Jagged Edges / Broken Lines / Misalignment

During the laser marking process, it is common to have problems such as ragged edges, broken lines, or misalignment.To address these three pain points, the company has developed a range of practical solutions, including parameter adjustment, equipment maintenance, and material compatibility. These help users quickly identify the root cause of problems and improve marking results, making equipment run more efficiently and stably.

What should be done about the rough edges that can sometimes appear on laser-etched markings?

Laser marking The "bite marks" left by laser marking not only look bad, they can also lower the pass rate of products.If you encounter these situations, don't rush to the repair shop. Try these solutions first.

Adjusting the power and speed parameters.

Most of the time, the ragged edges are the result of too much power or too low a speed.For instance, when marking metal, if the power is set above 80 %, heat buildup can produce burrs.I suggested reducing the power by 10 % and increasing the speed by 5-10 %, and testing the results on scrap.

Clean the lens and spray nozzle.

If the lenses are dirty, the laser beam will scatter, and the edges will become blurred.A dust-free cloth soaked in alcohol is used to wipe the lenses, and at the same time the nozzles are checked to see if they are clogged.Don't underestimate this step. Last month I wasted half a day because I had a dirty lens!

Check the compatibility of materials.

Some plastics or coatings are easily melted.If the material has a stubborn "rough edge," you can try putting a transparent protective layer on the surface of the material, or use a higher frequency marking mode.If that doesn't work, just change the materials--don't go head to head with the physical properties.

If your engraving has broken lines that look like dotted lines, try these techniques.

The most troublesome problem is the breaking of the thread, especially when the thread gets caught up while the pattern is being cut.The following methods have been proven effective.

Calibrating the galvanometer and motor.

If a mirror is off by as little as 0.1 millimeter, it can cause a wire to break.If the lines are not continuous, contact the after-sales service for dynamic calibration.When mixing yourself, be sure to wear an anti-static glove to prevent your sweat from affecting the delicate components.

Optimize the file path settings.

A vector file has too many nodes or sharp angles, causing the laser head to repeatedly accelerate and decelerate.If you use software to convert the Bezier curves into smooth paths, and add a 0.2 mm corner radius, you will find that the amount of broken lines is reduced by half.

Replacing worn-out parts.

If the equipment has been in use for more than two years, check the laser and bearings.One customer reported that a line kept stopping in the same place. It turned out that the wear on a sliding block on a guide rail was to blame. The problem was solved immediately by replacing the block, and the maintenance cost was much lower than the cost of a production stoppage.

The Final Guide to Resolving Labeling Errors.

There are two kinds of faulting: lateral displacement and vertical displacement.First, do a simple test. Print the same pattern three times in a row. If the misalignment is always in the same direction, follow the steps below.

Inspect the clamping device and the positioning sensor.

Eighty percent of the time it was because the material wasn't clamped tightly enough.Another solution is to use a vacuum suction fixture, or to attach a non-slip pad to the bottom of the material.If you're using an automatic feeding device, remember to wipe the photoelectric sensor's receiving window with an alcohol swab.

Upgrade control software.

Older versions of the software may have errors in the pulse counting.Last week, a customer who upgraded to version 3.2.7 saw his cumulative error drop from 0.3 mm per day to 0.02 mm.Remember to back up your parameters before upgrading, and don't ask me how I know that.

Environmental temperature control.

If the temperature in the workshop varies by more than 5 ° C, the metal framework will expand and contract, causing a change in the shape of the equipment by a micron or so.The company has added heat shields to the equipment, and every four hours it uses a laser thermometer to check the temperature of the critical parts. If the temperature exceeds 35 degrees Celsius, the equipment is stopped and allowed to cool.