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MACH 2008 BARA - IMRC

Laser Transformation of MDF. Four elements in the process: -MDF Laser SystemPowder CoatingConsortium of Trade Associations, University

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MACH 2008 BARA - IMRC

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    1. MACH 2008 BARA - IMRC J. Peter Hancocks Warwick IMRC Laser Transformation of MDF Friday 25th April 08

    2. Laser Transformation of MDF Four elements in the process: - MDF Laser System Powder Coating Consortium of Trade Associations, University & Industry partially funded by the Technology Strategy Board

    3. MDF – WHAT IS IT? Wood based composite Formed from wood fibres not particles Softwood, recycled timber, sawmill co-products used Held together by a resin Many grades including moisture and fire resistant

    4. MDF – WHY IS IT GOOD? Uses low grade wood and recycled materials to make a hardwood substitute Heat required to manufacture largely generated from burning timber waste Predictable properties Easily machined into profiled shapes No knots or bad grain areas

    5. MDF – WHY IS IT BAD? Many resins formaldehyde based But emission rates legally limited Alternative lignin based adhesives can be used Dust hazardous Dull appearance limits use Takes paint well

    6. MDF SPRUCED UP

    7. LASERS – Few of many applications Cutting – Metals, organics Drilling - Metals Marking- Metals, organics & ceramics Welding, Brazing Soldering – Metals Welding - Thermoplastics Heat Treatment – Metals Rapid Prototyping – Curing, sintering Nano & Micro Processing

    8. POWDER COATING Originally developed for metals Dry process – no solvents & little waste Mixture of pigment & resins electro-statically applied to object Cured in oven or by IR lamps Typically 10 minutes @ 180oC cure

    9. POWDER COATING Now applied to wood based & plastic objects Electro-static application requires some conductivity Wood based materials rely on moisture content Moisture can cause problems during cure

    10. The LaserCoat Project FIRA, TRADA & WMG considered using lasers to cure powder coating on 3D MDF and similar substrates Put together team & proposal for the LaserCoat project Included direct etching as well as coating Project started March 2006

    11. EARLY RESULTS

    12. Laser System

    13. NOT SO SIMPLE Too high moisture content

    14. NOT SO SIMPLE Expected laser to cure powder Actually just consolidated it Found that 10 minute 180oC powder took ~30 minutes in oven to fully cure on MDF substrate Poor heat transfer c.f. metal Out-gassing industry problem

    15. Complementary Processes

    16. Coated Examples from Sept 07

    17. Wood Coloured Panel Background & Grain Powder Coat

    18. Etched Examples from Sept 07

    19. OVER-PAINTED EXAMPLES SEPTEMBER 07

    20. VENEER BITMAP DEVELOPMENT BIGGER Scanner 150x150mm nominal Geometry allows 174x174 approx. Move table in X direction in controlled manner to ‘stretch’ image Move table in Y direction to place images side by side

    21. Bigger Panels 1

    22. Bigger Panels 2

    23. Bigger Panels 3

    24. Bigger Panels 4 Dither Scan Speed Table Speed %200W Focus Travel Light 0.05mm 5m/s 131mm/min 95% @ 900mm Dark 0.025mm 1m/s 59mm/min 95% @ 900mm

    25. Bigger Panels 5

    26. Bigger Panels 6

    27. Bigger Panels 7 Black Powder Coat MDF Profile Panels

    28. VENEER BITMAP DEVELOPMENT 3-D Still move table in X direction to ‘stretch’ image Still move table in Y direction to place images side by side but.. Profile repositioned to a new face Need to split Bitmap – Corel Draw

    29. 3-D Fixture

    30. 3-D Profiles - Etched Set Ups Dither Scan Speed Table Speed %200W Focus Travel Top 1 0.05mm 2.5m/s 375mm/min 75% @ 500mm Middle 2 0.05mm 2.5m/s 375mm/min 75% @ 500mm Lower 2 0.05mm 2.5m/s 375mm/min 75% @ 500mm

    31. 3-D Profiles - Coated Passes Dither Scan Speed Table Speed % 200W Focus Top 1 0.01mm 8m/s 300mm/min 40% @ Lower 2 0.025mm 8m/s 300mm/min 40% @

    32. Coated Profile Beige Flat 40% power 6000mm/sec 0.1mm dither Edge 25% power otherwise same. Oven post cure.

    33. Central Feature Profile ‘Flat 40% power 4000mm/sec 0.06 dither Edge 30% otherwise same.

    34. Square Edge Profile Etch details as above. Note machined surfaces darker

    35. Central Feature Profile Etched deep profile. Note semicircular feature edges etched as central to marking field. Settings as above.

    36. ECONOMICS & SCALE UP Demonstrated we have two workable processes, powder coating subject to a patent application Economics next to be explored Need elegant solutions Just big enough 24/7 versus 8/5 Low cost lasers

    37. CO2 Laser Plotter <=Ł2000! TRADA ORDERED

    38. The Partners

    39. Thank You

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