How to Solve Serrated Edges in Laser Marking

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How to solve the problem of jagged edges when marking with a laser marking machine?

The serrated edges that appear when marking with a laser marking machine not only affect the aesthetic appeal of the marking but may also lead to a decrease in marking accuracy. The following are the causes of marking sawtooth and their solutions:

I. Cause Analysis

(1) Improper setting of laser parameters
1. Excessive scanning speed: An overly fast scanning speed can prevent the laser energy from fully acting on the material surface, resulting in unclear line edges and jagged edges.
2. Setting the power too high or too low: Setting the power too high may cause excessive ablation of the material, while setting it too low may result in the marking being too shallow. Both can lead to sawtooth.
3. Unreasonable frequency setting: High frequency is suitable for shallow marking, while low frequency is suitable for deep engraving. If the frequency is set improperly, it may cause the edge of the mark to be not smooth.

(2) Optical system issues
Optical component contamination: Dust, oil stains and other contaminants on the surface of the lens can affect the transmission and focusing effect of the laser, resulting in sawtooth marking.
2. Optical path offset: Optical path offset or inaccurate installation of optical components can cause the focus point of the laser beam to deviate from the set position.

(3) Mechanical structure issues
1. Decline in galvanometer accuracy: The galvanometer is a key component of the laser marking machine. If the movement accuracy of the galvanometer decreases or malfunctions, it will lead to marking sawtooth.
2. Uneven worktable: An uneven or deformed surface of the worktable will affect the focusing effect of the laser beam.

(4) Material Properties
1. Uneven material surface: If the material surface is uneven or has unevenness, the focus points of the laser beam on the material surface will be inconsistent, resulting in sawtooth marking.
2. Thermal expansion of materials: Some materials may undergo thermal expansion under the influence of lasers, leading to deformation of the marking.

(V) Software issues
1. Insufficient graphic preprocessing: If the input vector graphics have not undergone adequate preprocessing, such as insufficient resolution or excessively high graphic complexity, it may lead to jagged marking.
2. Incorrect software parameter Settings: Improper setting of marking parameters in the software (such as DPI, fill spacing, etc.) may also lead to marking sawtooth.

Ii. Solutions

(1) Optimize laser parameters
1. Adjust the scanning speed: Appropriately reduce the scanning speed to ensure that the laser energy can fully act on the material surface and improve the sawtooth phenomenon.
2. Adjust power: Set the laser power reasonably based on the material properties. It is recommended to start testing at 70% of the device's recommended value and make gradual fine-tuning.
3. Adjust the frequency: Select an appropriate pulse frequency based on the required marking depth. High frequency is suitable for shallow marking, while low frequency is suitable for deep engraving.

(2) Clean and calibrate the optical system
1. Clean optical components: Use a lint-free cloth and high-purity isopropyl alcohol (IPA) or acetone to gently wipe the optical lenses to remove surface dirt.
2. Calibrate the optical path: Use professional tools to calibrate the optical path to ensure that the laser beam can be accurately focused on the material surface.

(3) Inspect and maintain mechanical structures
1. Check the galvanometer: Inspect the motion accuracy of the galvanometer and calibrate or replace it if necessary.
2. Inspect the workbench: Ensure that the surface of the workbench is flat. Adjust or replace it if necessary.

(4) Treat the surface of the material
1. Select high-quality materials: Ensure that the surface of the materials is smooth, clean, free of impurities or oil stains.
2. Pre-treatment of materials: Grind or polish the surface of the materials to reduce the impact of surface unevenness on marking.

(V) Optimize software Settings
1. Graphic preprocessing: Convert vector graphics to bitmaps with a resolution of 300-600 DPI and eliminate aliasing.
2. Adjust software parameters: Reasonably set the marking parameters in the software, such as DPI and fill spacing, to ensure that the marking effect meets the requirements.

Iii. Preventive Measures

(1) Regularly maintain the equipment
1. Regularly clean optical components: Clean the optical components once a week to ensure their surfaces are clean.
2. Regularly calibrate the optical path: Conduct a comprehensive calibration of the optical path once a month to ensure the accuracy of the laser beam's focus point and scanning path.

(2) Optimize the working environment
1. Control temperature and humidity: Ensure that the equipment operates in a suitable environment. The temperature should be controlled between 15 and 35℃, and the humidity should be less than 60%.
2. Reduce vibration: Ensure that the equipment is placed on a stable ground to avoid vibration affecting the marking accuracy.

(3) Set parameters reasonably
1. Establish a parameter matrix table: Based on the material type and marking requirements, establish a parameter matrix table to facilitate the quick invocation of the optimal parameters.
2. Test marking: Before the formal marking, conduct test marking to observe whether the marking effect meets the requirements.

By the above methods, the problem of sawtooth in laser marking machines can be effectively solved, improving the marking quality and the stability of the equipment. If the problem still cannot be solved, it is recommended to contact the equipment manufacturer or professional maintenance personnel for inspection and repair.

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