Abstract: A multi-layer device assembly system including a substrate source, a plurality of dispenser modules, a feeder, a control system having a number of alignment cameras corresponding to the dispenser modules, an inspection camera, and a defect camera. The substrate source provides a substrate having a plurality of base elements. Each dispenser module includes an actuation mechanism configured to laminate a layer element onto one of the base elements or onto a previously laminated layer element. The feeder metes out the substrate from the substrate source to advance each base to a subsequent dispenser module between lamination steps. The control system determines alignments, defects, and lamination errors via the alignment cameras, inspection camera, and defect camera.

Abstract: A laser system and method for inspecting a substrate and/or a laser score formed in a moving web of material during laser processing of the material with a laser processing system having a laser source for generating a laser beam and a lens for focusing the laser beam and reflecting the laser beam onto the advancing web of material where the focal point is directed a selected location on the web to produce the score in the advancing web of material, the score having a depth less than the thickness of the material and measuring the depth at one or more locations on the advancing web of material concurrent with producing the score line and where the material may be a packaging material and the score provided for easy opening of the packaging.

Abstract: A laser beam trimming and redirecting device having an aperture therein, the aperture defined by a inner beveled surface for focusing the laser beam directed therethrough and the aperture having an outer beveled surface, or beveled edge, for trimming the laser beam and reflecting the excess energy back towards a source at an angle other than 180 degrees. A reflection capture device positionable upstream of the trimming and redirecting device is configured to absorb the reflected energy instead of the laser beam source or delivery components. The capture device is a liquid cooled device so as dissipate the heat energy absorbed preventing degradation of the device.

Abstract: An assembly and method of reducing discoloration of a foam material resulting from laser processing the material comprising an assembly configured for positioning below the material being processed and for directing air into open cells of the open-cell foam material to pressurize the material during laser processing. The assembly comprises an air delivery mechanism comprising one or more apertures for an air chamber positioned directly below the material travel path. Aligning the one or more apertures with the axis of the laser beam and its focal point when the material is positioned above the one or more apertures and pressurizing or filling of the open cells with air in the direct vicinity of the target area reduces processing related discoloration of the material. The cells are laser processed concurrently with pressurization thereby substantially reducing settling of debris and smoke on the material and reducing discoloration.

Abstract: A laser processing system includes a metal platform having a metal surface wherein at least a portion of the platform surface is substantially planar with a substantially smooth topography. A laser source is configured to generate a laser beam having a focal point that is directed toward a substantially planar portion of the platform surface. A motion mechanism is configured to move at least one of the metal platform and the focal point along at least one axis. A restraining mechanism restrains a film against the platform surface such that an adjoining surface of the restrained film remains in intimate contact with the surface. A controller is configured to operate the laser source, the motion mechanism or both to cut the restrained film in a predetermined pattern with a generated laser beam such that the cut does not extend through the adjoining surface of the restrained film.

Abstract: A rotary die apparatus and method for three-axes registration error correction. The rotary die apparatus includes a rotary die for applying patterns to a strip of material, a sensor for sensing fiducials on the strip of material, actuators to adjust the rotary die, and a control system. The actuators adjust the rotary die along an X-axis extending along a direction of travel, along a Y-axis transverse of the direction of travel, and about a theta axis perpendicular to the X-axis and the Y-axis. The control system calculates a registration error based on a difference between an actual location or orientation of the fiducials and a desired location or orientation of the fiducials. Then the control system outputs control signals to the actuators to adjust the rotary die along the X-axis, along the Y-axis, and/or about the theta axis while the rotary die continues to rotate.

Abstract: A system and method of cooling and purging a laser processing system comprising at least one galvo system for directing at least one laser beam to a work piece and a protection window mounting plate comprising at least one protection window secured in a corresponding cavity of the mounting plate where the plate is configured with at least one air flow passageway in the mounting plate for each protection window such that an airflow used to cool each galvo systems is directed through the mounting plate vis the passageway and further directed past the window cavity to purge the cavity, where the purging air flow is then vented or exhausted from the laser system.

Abstract: A laser cutting machine includes at least one galvo having a galvo field of view in which the galvo can cut a material moving with a speed past the galvo. A display in the machine provides an image of at least one pattern to be cut from a material, the pattern comprising of a plurality of objects with each object having a position on the material and each object comprising at least one cut. An optimizer in the machine receives the position on the material of each object of the pattern and assigns a start locations for each cut of each object and a trigger distance for each object to maximize the speed at which the material moves past the galvo while ensuring that each object is cut by the galvo at the object's respective position on the material.

Abstract: A multi-layer device assembly system including a substrate source, a plurality of dispenser modules, a feeder, a control system having a number of alignment cameras corresponding to the dispenser modules, an inspection camera, and a defect camera. The substrate source provides a substrate having a plurality of base elements. Each dispenser module includes an actuation mechanism configured to laminate a layer element onto one of the base elements or onto a previously laminated layer element. The feeder metes out the substrate from the substrate source to advance each base to a subsequent dispenser module between lamination steps. The control system determines alignments, defects, and lamination errors via the alignment cameras, inspection camera, and defect camera.

Abstract: The present invention includes methods for treating laser-processed materials having an odor generated during the laser processing. The present method includes treating the laser-processed materials with heat to dissipate the odor from the material. The laser processed material may be secured to avoid curling during the heating process. The method can also include a cooling step after heating of the laser-processed material. Multiple cycles of heating and cooling may also be performed to substantially reduce or eliminate the odor from the laser-processed material. The invention also includes articles made according to the method and apparatus for producing laser processed materials having substantially reduced odor.

Abstract: An apparatus that divides a single laser beam into two or more beams that can be directed at an object, such as a work piece, to perform laser heat treatment is disclosed. An adapter stage is in optical communication with a light source, such as a laser source, and arranged to receive a light beam from the light source. A focus stage in optical communication with the adapter stage is arranged to receive the light beam from the adapter stage and to focus the light beam. A beam splitting stage in optical communication with the focus stage is arranged to receive the focused light beam and to split the focused light beam into a multiple light beams. A redirection stage in optical communication with the beam splitting stage is arranged to receive the multiple light beams and to direct them toward a plurality of target locations on the object.

Abstract: A system and method for laser processing a complex pattern and a perimeter around the complex pattern on a moving web, the complex pattern and the perimeter processed continuously with a single laser. The complex pattern may be a plurality of holes such that cutting of the perimeter forms a disk having multiple holes. The plurality of holes are interior to the disk and laser processed using a camming program while a web of material is continuously moving. The laser is then repositioned to cut the perimeter while the laser remains on and the web is continuously moved. The multi-hole disk may be cut from a continuous roll of abrasive material.

Abstract: A rotary die apparatus and method for three-axes registration error correction. The rotary die apparatus includes a rotary die for applying patterns to a strip of material, a sensor for sensing fiducials on the strip of material, actuators to adjust the rotary die, and a control system. The actuators adjust the rotary die along an X-axis extending along a direction of travel, along a Y-axis transverse of the direction of travel, and about a theta axis perpendicular to the X-axis and the Y-axis. The control system calculates a registration error based on a difference between an actual location or orientation of the fiducials and a desired location or orientation of the fiducials. Then the control system outputs control signals to the actuators to adjust the rotary die along the X-axis, along the Y-axis, and/or about the theta axis while the rotary die continues to rotate.

Abstract: An embossing/debossing system and method for embossing or debossing an impressionable material, such as paper. The system may comprise a laser cutting apparatus and a stamping apparatus. The laser cutting apparatus may comprise a laser configured for cutting and/or ablating one or more patterns into a stencil material. The stamping apparatus may be configured to receive the stencil material from the laser cutting apparatus and may have an actuatable elastomeric press pad configured to press the impressionable material into the patterns formed in the stencil material by the laser cutting apparatus. The system may also comprise various feeding devices configured to feed the stencil material from the laser cutting apparatus to the stamping apparatus and/or configured to feed the impressionable material through the stamping apparatus.

Abstract: A variable air access mechanism and method of varying air access comprising a first film with a predetermined amount of total air access openings to be formed by removal of laser cut chads; a portion of the chads only partially cut; and a second film adhered to the first film wherein removal of the second film in a first direction opens all of the air access openings or removal of the second film in an opposing direction leaves the partially cut chads attached to the first film such that only selected chads are removed.

Abstract: A laser processing system includes a metal platform having a metal surface wherein at least a portion of the platform surface is substantially planar with a substantially smooth topography. A laser source is configured to generate a laser beam having a focal point that is directed toward a substantially planar portion of the platform surface. A motion mechanism is configured to move at least one of the metal platform and the focal point along at least one axis. A restraining mechanism restrains a film against the platform surface such that an adjoining surface of the restrained film remains in intimate contact with the surface. A controller is configured to operate the laser source, the motion mechanism or both to cut the restrained film in a predetermined pattern with a generated laser beam such that the cut does not extend through the adjoining surface of the restrained film.

Abstract: A method of scoring a multi-layer film structure, wherein the multi-layer film structure comprises a metal layer and polymer layer bonded to each other, the method comprises using a single laser beam incident to the polymer layer to produce a score line in the polymer layer, wherein the laser energy is absorbed only by the metal layer.

Abstract: An embossing/debossing system and method for embossing or debossing an impressionable material, such as paper. The system may comprise a laser cutting apparatus and a stamping apparatus. The laser cutting apparatus may comprise a laser configured for cutting and/or ablating one or more patterns into a stencil material. The stamping apparatus may be configured to receive the stencil material from the laser cutting apparatus and may have an actuatable elastomeric press pad configured to press the impressionable material into the patterns formed in the stencil material by the laser cutting apparatus. The system may also comprise various feeding devices configured to feed the stencil material from the laser cutting apparatus to the stamping apparatus and/or configured to feed the impressionable material through the stamping apparatus.

Abstract: A method for preventing a plume from contaminating a surface of material that has been cut by a laser or focusing optic wherein the laser produces the plume, the method comprises providing a first airflow beneath the plume with the airflow redirecting the plume away from the surface of the material. A second airflow is provided to further lift the plume to an exhaust. Apparatus is configured to direct first and second air flows such that the plume is not deposited on the material being cut by the laser or on the focusing optic.

Abstract: An embossing/debossing system and method for embossing or debossing an impressionable material, such as paper. The system may comprise a laser cutting apparatus and a stamping apparatus. The laser cutting apparatus may comprise a laser configured for cutting and/or ablating one or more patterns into a stencil material. The stamping apparatus may be configured to receive the stencil material from the laser cutting apparatus and may have an actuatable elastomeric press pad configured to press the impressionable material into the patterns formed in the stencil material by the laser cutting apparatus. The system may also comprise various feeding devices configured to feed the stencil material from the laser cutting apparatus to the stamping apparatus and/or configured to feed the impressionable material through the stamping apparatus.