Download - The material thickness was halved without compromising quality new accessible markets

1Commercially Confidential DD Monthname 200X

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We developed an innovative CO2 laser based solution for a non contact web perforator, giving our client, British Polythene, commercial advantage

• Our client needed to perforate a new thinner plastic web with large holes but standard mechanical methods were inadequate, causing tearing

• We carried out materials development to optimise the non contact, laser, processing capability without compromising web strength

• We developed and installed a fully robust and safety compliant system suitable for unskilled operators

• Our unique design of laser perforator, needed to meet the demanding production rates has provided a protectable solution for the client


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Our client gained commercial advantage with quality product meeting environmental requirements and a unique, protected process

• The material thickness was halved without compromising quality– new accessible markets– lower disposal taxes– lower material consumption

• Our client has patent protection for the solution– we filed on his behalf– the technology can be licensed


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We installed a fully robust and safety compliant system

• We installed the system safely with minimal production downtime

• We applied our experience in – laser systems– complex optical element design– precision opto mechanics– machine and system control engineering

• The system is CE compliant

• It is safe for unskilled operators

• System safety was challenging: – 1.7kW CO2 laser beam (Class 4) – parts rotating at up to 800rpm– high voltage (many kV)– toxic fumes and aerosols


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We carried out materials development to optimise the processing capability

• 10mm diameter hole

• More than 500 holes per second

• Wide web: 2.5m wide

• Standard line speed: 80m/min

• We modified the material for resonant, ablative cutting

– Non blocking cutting of two layers of web simultaneously

– No layer adhesion

• We maintained mechanical properties with thinner material, almost 1/3 of previous thickness

• We used only process and industry compatible materials e.g. clays


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We developed a robust optical solution to meet the extremely demanding requirements

• The optical beam is directed to the web sequentially by a rotating drum

• All parts are positioned to better than 20m

• We designed a custom Axicon lens solution to form the beam shape

• We selected an optimum but robust laser

Download - The material thickness was halved without compromising quality new accessible markets

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