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CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using Laser Engraving in Tissue Embossing This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Presented by Carl Ingalls, Embossing Technologies Ed Giesler, Giesler Enterprises Inc. Ingalls & Giesler 1 CMM International 2003 Conference This Thisslide slidepresentation presentationwas wascreated createdby byCarl CarlIngalls Ingallsand andEd EdGiesler Gieslerfor forCMM CMMInternational International2003 2003Conference Conference Tissue Products With Embossing Napkins Always embossed Paper towels Usually embossed Bath tissue Often embossed Facial tissue Rarely embossed Ingalls & Giesler 2 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Rotary Embossing Process Schematic Engraved roll Paper path Rubber covered roll Rolled product Ingalls & Giesler 3 CMM International 2003 Conference Tissue Embossing Applications for Laser Engraved Rolls – Today This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference • Evaluating new embossing patterns. • Making steel rolls from laser engraved rolls. • Short production runs. • Long-term use in production. Very Special Cases. • This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003. Ingalls & Giesler 4 CMM International 2003 Conference Advantages and Disadvantages of Laser Engraving – Compared to Conventional Steel This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Advantages Disadvantages • Less expensive, on a per engraving basis. • Shorter life, requiring more frequent re-engraving. • Faster delivery time. • • This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003. Easily damaged – during shipping, handling, and in use. • Higher accuracy in positioning the pattern elements on the surface of the roller. • Less accurate control of depth, sidewall shape, and curvatures (“radiusing”). continued to next slide … Ingalls & Giesler 5 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Advantages and Disadvantages, continued Advantages Disadvantages • Complete digital control of the image, computer to computer, even when engraving large rolls. • The technology for copying the contour of an existing surface into a computer is not as accurate. • The ability to use more complex patterns. • Poorer quality surface finish. • This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003. Ingalls & Giesler 6 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Laser Engraving Process Today Start with a smooth steel roll. Put the roll into the laser machine and start it turning. CREATED BY CARL INGALLS AND Cover the roll with a laser-engravable material. Cure the coating, and grind smooth. Program the laser with the pattern to be engraved. ED GIESLER FOR CMM INTERNATIONAL 2003 Energize the beam !! Engraving is done. Clean the roll, box it, and ship it. Ingalls & Giesler 7 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Laser Engraving Technologies: Etch Profiles metallic mask 2D 2D Enhanced 3D “Square” profile 2-Level Vertical walls “Mesa” profile 2-Level Sloped walls Any profile Multi-Level Complex contours CREATED BY CARL INGALLS AN D CREATED BY CARL INGALLS AN D CREATED BY CARL INGALLS AN D ED GIESLER FOR ED GIESLER FOR ED GIESLER FOR CMM INTERNATIONAL 2003 CMM INTERNATIONAL 2003 CMM INTERNATIONAL 2003 Ingalls & Giesler 8 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference More About Profile Geometry sidewall angle engraved depth sidewall shoulder radius A single boss fillet radius A Single Boss Created by Carl Ingalls and Ed Giesler for CMM International 2003 An engraved embossing roll CREATED BY CARL INGALLS AND ED GIESLER FOR CMM INTERNATIONAL 2003 Ingalls & Giesler 9 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Problem of “Nesting” in a Roll of Product Nesting band AntiNesting band CREATED BY CA RL INGALLS AN D ED GIESLER FO R CMM INTERNATI ONAL 2003 Ingalls & Giesler 10 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Problem of “Ridging” in a Roll of Product Machine Direction (MD) Extreme MD alignment aligned slanted Slightly slanted from MD Ingalls & Giesler 11 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Embossing with Laser Engraved Cylinders • R&D Embossing – good for short runs – laser engraved removable sleeves • Production Embossing – practical in only very special situations – useful life anywhere between a few hours and several months Ingalls & Giesler 12 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using a Laser with Acid to Engrave Steel 1. Start with a smooth steel roll. Cover with acid resistant coating. CREATED BY CARL INGALLS AND ED GIESLER FOR CMM INTERNATIONAL 2003 2. Put the coated roll into a laser. Burn a pattern thru the coating. 3. Spray the roll with acid. The acid etches the unprotected areas of steel. continued to next slide … Ingalls & Giesler 13 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using a Laser with Acid to Engrave Steel (cont.) 4. Continue with the same roll … add more protective coating … repeat until desired depth is reached. CREATED BY CARL INGALL S AND ED GIESLER FOR CMM INTERNATIONAL 2003 laser acid engrave etch coating metal 3002 lanoitanretnI MMC rof relseiG dE dna sllagnI lraC yb detaerC Ingalls & Giesler 14 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Why We Cannot Acid Etch in One Step Acid will etch in all directions at once, and can cause undercutting if not controlled by repeated application of the protective coating. Pattern put into the coating, either by mechanical pressure or by laser etch. Created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003 Coating Steel base Ingalls & Giesler 15 CMM International 2003 Conference Copying & Multiplying a Pattern: From Tooling Through Production Roll This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Begin with … Intermediate Tooling Original Tooling This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003 … that has the pattern already engravedMaster into it. Roll (optional) Final Production Roll Ingalls & Giesler 16 CMM International 2003 Conference Stepping a Tool Across a Roll to Multiply the Pattern This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The upper roll is a tool, which may be conventional or laser engraved. The lower roll must be steel for the acid etch process to work. Ingalls & Giesler 17 CMM International 2003 Conference Making a Pattern Transfer (Copy) From One Roll to Another This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Start with a roll that is already engraved with the pattern … … and a blank roll that is to be engraved. Bring the rolls together, so that wax is squeezed out at the contact points. Start the rolls turning together, to transfer the pattern to the wax. Bring in an acid bath Cover the blank roll with an acidresistant wax coating. … to etch away the unprotected steel. Ingalls & Giesler 18 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference What’s In It For The Laser Engravers • • • • • Acquire customer contacts. Understand embossing applications. Learn required laser size and capability. Learn what other changes are needed. Understand how to prioritize all the above. Ingalls & Giesler 19 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Challenges for Laser Engravers • MATERIALS Find or develop a wear resistant covering that is comparable to chrome plated steel • 3D Method to do sophisticated contour engraving • QUALITY Improve surface finish • ACCURACY Improve dimensional tolerances - (M/S) Ingalls & Giesler 20 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Reactions from Conventional Engravers • PAST Experimental use only (trial rolls). Everyone was Happy • PRESENT Making Tooling & Master Rolls, plus trial rolls. Making only a few production rolls. Still mostly OK • FUTURE Anything could happen … Proactive and/or Concerned Ingalls & Giesler 21 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Conclusion • Laser engraved rolls are here now. • The future depends upon continued developments: – – – – Composition of the surface to be engraved. Capabilities of the laser engraving machines. Laser engraving process technology. Using laser engraved rolls to make steel embossing rolls. – Learning how to reduce the wear on laser engraved embossing rolls. Ingalls & Giesler 22 CMM International 2003 Conference This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Thank You for Your Participation !! We welcome your questions at any time • At the CMM Conference • By phone • By email Carl Ingalls Ed Giesler 610-627-9030 920-434-1715 [email protected] [email protected] www.EmbossingTechnologies.com Ingalls & Giesler 23