LAP3D - Laser processing system for stitching structured patterns on large 3D parts

Challenge

The assessment will implement a mechano-optical solution to process curved surfaces with an acceptance angle of up to 270º. The challenge is to control the combined motion of the beam delivery system with respect to distortion of the motifs and positioning tolerances. Herein, the required precision is defined by the visually perceived quality expectation of the customer. The target structuring rate of 400mm/s marks the economic performance requirement for such a 3D system which requires fast and precise control software.

Benefit

LAP3D will enable manufacturers to offer individualised marking for large products, even in mass markets. The application to plastic parts in the automotive industry opens a full set of truly innovative aesthetic options which efficiently serve customer demands within an economic budget.

The Maier Group as the user in LAP3D aims at extending current limits in laser-based decoration of large 3d parts. The technology will enable the provision of the same decorative marking on virtually all parts of the car interior and exterior. In recent times, the decision impact of car aesthetics overrules technical performance and reliability in many cases. A successful implementation of the new technology will provide a significant competitive advantage for the automotive suppliers. Other markets such as furniture and architecture are already prepared to take up similar applications.

Achievement

LAP3D develped a control software, suitable for two dimensional problems. With the new software, the robot can translate the required shape design to 3D. Continuously adjusting the focus position allows for a mark-free motif. Another software solution was implemented that controls the six DOF (degrees of freedom) - system marking on a 2D-surface that involves all drives.In addition to the control software, a quality control system has been developed. Based on machine vision it inspects all the parts after completion. It can detect pattern distortions and displacements, as well as changes in contrast between the pattern and the surrounding area. End-user Maier Group profits from LAP3D’s 3D-marking technology by being able to apply it
successfully to components for the
automotive industry. Innovative computer-based process controlling will allow more flexible and individualized options for marking. Supplier Rofin can improve its product portfolio, thus positioning the company as a leader in the decorative automotive field, accessing train or aircraft manufacturing markets, billboards or panels, furniture etc.