Wire and Cable

Capabilities and Limitations of Laser Marking Wire PDF

Lasers Power High Speed Marking & Stripping PDF


Laser Wire Marking

Marking wire and cable at high speeds, using “On-The-Fly” (OTF) technology pioneered by CMS Laser, allows your company to achieve production rates that are unachievable by any other method. CMS Laser’s r wire marking systems can reach throughput rates in excess of 600 feet per minute and put virtually any mark, font, or character onto the wire at those speeds. They even account for variations in speed, and will still mark accurately were the feed to be constantly accelerated or decelerated.

These wire marking systems use state of the art ultraviolet lasers which interact with the wire’s surface and write with spot sizes as small as 0.001″. Laser wire markers provide a high quality, high contrast, permanent, non-contact method for marking coated wire and multi-core cable with alphanumeric characters, graphics or barcode information for identification. These marking systems are a reliable, clean, high speed, low maintenance alternative to non-permanent and high-maintenance methods such as direct ink or hot stamping. Unlike hot stamping, laser wire marking does not cause damage or change to the electrical or mechanical properties of the wire and will not wear off due to solvents or friction. It maintains complete insulation integrity and is accepted as a manufacturing process within the international aerospace industry.

How Laser Wire & Cable Marking Works

Ultra violet (UV) laser wire marking is accomplished by the absorption of the radiation on the surface of the insulation that creates a reaction with the UV-sensitive pigments known as titanium dioxide or TiO2. This reaction causes the TiO2 particles that are contained within the insulation to change colors by rearranging their crystalline structure on a microscopic scale, leaving a high contrast blackish color on white insulation. The mark is embedded about 20 microns (0.0008 inch) into the insulation surface, creating a durable mark with resistance against abrasion and fluids.

Advantages of Laser Marking Wire & Cable

Our system is designed for ease of use, increased productivity and reduced labor costs. The high speed On-The-Fly (OTF) marking has a throughput in excess of 120 inches/second and will effectively mark on white or colored insulation including PTFE (Teflon®), ETFE (Tefzel®), XLETFE and FEP. These fluoropolymer materials can generally be marked on in all forms such as dispersion topcoats, extruded polymers and thin tapes. In addition, single core, twisted pair, multicore cables and round cables can be accommodated.

CMS Laser systems can print graphics and images, and text can be marked in various fonts and sizes, either vertically or horizontally, with no masking required. The text can originate from the job/assembly file, or can optionally originate from an MES system over a high-speed network connection.

Other features include infinite text lengths, infinite variable end mark distances, and infinite variable continuous mark distances. Identical text marking or optional programmable text for each end of the wire can also easily be accomplished. With the serialization option set, the date code and time stamp can automatically be marked on each wire for tracking purposes. UV laser marking is the specified method used in civil and military programs of aircraft manufacturers and their subcontractors, maintenance organizations and wire manufacturers worldwide.

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Laser Wire Stripping

CMS Laser wire stripping systems cut around, and optionally, down the length of the insulating materials which cover the metal conductors. This wire stripping process allows the insulation to subsequently be pulled off very easily at a later time. Laser wire stripping is the most precise and reliable stripping method available today. It uses a non-contact method that eliminates the risk of damage to the conductor or shield. By using the proper laser type for a particular wire, the insulation will absorb the beam and be vaporized, whereas the metallic materials of the underlying wire conductor will reflect the laser beam and will not be damaged.

Our laser wire system can process stripping lengths from 0-4 inches on various types of insulation materials, such as enameled coatings, epoxy, ETFE, fiberglass, Formvar, Kapton, Kynar, Milene, Mylar, nylon, silicone, polyester, polyesterimide, polyethylene, polyimide, polyvinylidene fluoride, polyurethane, polyvinyl chloride, and Teflon.

Versatility of Wire & Cable Laser Stripping Systems

Wire stripping can remove the insulation from many types of wire and cable including single-core wire; twin leads; shielded twisted pairs; multi-conductor cables; shielded and screened wire and cable; ribbon cable; coaxial cable; and complex 2D- and 3D-shaped conductors, such as coils. In addition, a wide range of wire sizes can be processed without requiring tool changes and wire sizes can range from 28 gauge to 6 gauge (14mm OD max). Ribbon and flat cable can be up to 11.4 inches wide.

Other stripping features of the laser wire system include a variety of wire stripping modes to allow slugs to remain on the wire strands, mid-wire (windowing) laser strip capabilities, on-the-fly stripping options, and excellent precision with a strip length accuracies within +/- 0.10 inches.

Advantages of Wire & Cable Stripping Laser Systems

With this innovative technology there are no disposal issues of hazardous chemicals, no costly blades to replace or sharpen at regular intervals and no high electrical currents to contend with. Laser wire stripping provides outstanding levels of quality, reliability and productivity in addition to meeting the high standards for conductor damage set by NASA and the Federal Aviation Administration.

The wire and cable industry has found extraordinary value in laser marking, and laser stripping systems from Control Micro Systems. We pioneered On The Fly wire technology systems, and we continue to lead the way today.

View List of Our Capabilities by clicking the links below

Laser CuttingLaser Drilling | Laser Marking | Laser Welding | On The Fly Technology

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