This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using Laser Engraving in Tissue Embossing Presented

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference


Using Laser Engravingin Tissue Embossing

Presented by

Carl Ingalls, Embossing Technologies

Ed Giesler, Giesler Enterprises Inc.

CMM International 2003 Conference

1Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 ConferenceThis slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference

Tissue Products With Embossing


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Always embossedNapkins

Usually embossedPaper towels

Often embossedBath tissue

Rarely embossedFacial tissue

Ingalls & Giesler


Rotary Embossing Process Schematic


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Paper path

Engraved roll

Rubber covered roll

Rolled product

Ingalls & Giesler

• 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.

• Evaluating new embossing patterns.

• Making steel rolls from laser engraved rolls.

• Short production runs.

• Long-term use in production. Very Special Cases.

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 ConferenceTissue Embossing Applicationsfor Laser Engraved Rolls – Today


4Ingalls & Giesler


• Less expensive, on a per engraving basis.

• Shorter life, requiring more frequent re-engraving.

• Faster delivery time. • 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”).

Advantages and Disadvantages of Laser Engraving – Compared to Conventional Steel


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continued to next slide …

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


• The ability to use more complex patterns.

• Poorer quality surface finish.

• 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.

Advantages and Disadvantages, continued


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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


The Laser Engraving Process Today


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Start with a smooth steel roll.

Cover the roll with a laser-engravable material.

Program the laser with the pattern to be engraved.

Energize the beam !!

Put the roll into the laser machine and start it turning. C R E A T E D B Y C A R L I N G A L L S A N D

E D G I E S L E R F O R

C M M I N T E R N A T I O N A L 2 0 0 3

Engraving is done. Clean the roll, box it, and ship it.

Cure the coating, and grind smooth.

Ingalls & Giesler


Laser Engraving Technologies: Etch Profiles


2D “Square” profile

2-Level

Vertical wallsC R E A T E D B Y C A R L I N G A L L S A N D



2D Enhanced“Mesa” profile

2-Level

Sloped wallsC R E A T E D B Y C A R L I N G A L L S A N D



3D Any profile

Multi-Level

Complex contoursC R E A T E D B Y C A R L I N G A L L S A N D



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metallic mask

Ingalls & Giesler


More About Profile Geometry


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An engraved embossing rollC R E A T E D B Y C A R L I N G A L L S A N D



A single bossengraved

depth

A Single BossCreated by Carl Ingalls and Ed Giesler for CMM

International 2003

sidewall

sidewall angleshoulder

radius

fillet radius

Ingalls & Giesler


The Problem of “Nesting” in a Roll of Product


Nesting band

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Anti-Nesting

bandC R E A T E D B Y C A R L I N G A L L S A N D



Ingalls & Giesler


The Problem of “Ridging” in a Roll of Product


Machine Direction

(MD)

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Extreme MD alignment alignedalignedslanted Slightly slanted from MD

Ingalls & Giesler


• 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

Embossing with Laser Engraved Cylinders


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• 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


2. Put the coated roll into a laser.

Using a Laser with Acid to Engrave Steel


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1. Start with a smooth steel roll.

Cover with acid resistant coating.C R E A T E D B Y C A R L I N G A L L S A N D



3. Spray the roll with acid.

The acid etches the unprotected areas of steel.

continued to next slide …Ingalls & Giesler

Burn a pattern thru the coating.

… repeat until desired depth is reached.C R E A T E D B Y C A R L I N G A L L S A N D




Using a Laser with Acid to Engrave Steel (cont.)


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4. Continue with the same roll …

3002 lanoitanretnI MMC rof relseiG dE dna sllagnI lraC yb detaerC

add more protective

coating

laser engrave coating

acid etch metal

Ingalls & Giesler


Why We Cannot Acid Etch in One Step


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Acid will etch in all directions at once, and can cause undercutting if not controlled by repeated application of the protective coating.

Steel base

Coating

Ingalls & Giesler

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

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 ConferenceCopying & Multiplying a Pattern:From Tooling Through Production Roll


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Master Roll (optional)

Final Production Roll

Original ToolingThis slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003

Intermediate Tooling

copycopy

copy

copy

… that has the pattern already engraved into it.

Begin with …

Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 ConferenceStepping a Tool Across a Rollto Multiply the Pattern


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The lower roll must be steel for the acid etch process to work.

The upper roll is a tool, which may be conventional or laser engraved.

Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 ConferenceMaking a Pattern Transfer (Copy)From One Roll to Another


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Start with a roll that is already engraved with the pattern …

… and a blank roll that is to be engraved.

Cover the blank roll with an acid-resistant wax coating.

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

… to etch away the unprotected steel.

Ingalls & Giesler


• 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.

• 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.

What’s In It For The Laser Engravers


19Ingalls & Giesler


• MATERIALSFind or develop a wear resistant covering that is comparable to chrome plated steel

• 3D

Method to do sophisticated contour engraving

• QUALITYImprove surface finish

• ACCURACYImprove dimensional tolerances - (M/S)

Challenges for Laser Engravers

• MATERIALSFind or develop a wear resistant covering that is comparable to chrome plated steel

• 3D

Method to do sophisticated contour engraving

• QUALITYImprove surface finish

• ACCURACYImprove dimensional tolerances - (M/S)


20Ingalls & Giesler


• PASTExperimental use only (trial rolls). Everyone was Happy

• PRESENT Making Tooling & Master Rolls, plus trial

rolls.Making only a few production rolls. Still mostly OK

• FUTUREAnything could happen … Proactive and/or Concerned

• PASTExperimental use only (trial rolls). Everyone was Happy

• PRESENT Making Tooling & Master Rolls, plus trial

rolls.Making only a few production rolls. Still mostly OK

• FUTUREAnything could happen … Proactive and/or Concerned

Reactions from Conventional Engravers


21Ingalls & Giesler


• 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.

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.


22Ingalls & Giesler


Thank You for Your Participation !!

We welcome your questions at any time• At the CMM Conference• By phone• By email


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Carl IngallsEd Giesler

610-627-9030920-434-1715

[email protected] [email protected]

www.EmbossingTechnologies.com

Ingalls & Giesler

Documents

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using Laser Engraving in Tissue Embossing Presented