LASCAM systems: Unique taillight design thanks to laser decoating

Laser decoating

Laser decoating, or 3D selective removal of plated layers, is a modern laser technology that allows the removal of the plated layer with minimal impact on the underlying material to within hundredths of a millimetre. The process preserves all the optical characteristics of the headlamp, reduces costs and production time, while creating patterns that cannot be achieved with any other technology. The final effect when the light is switched on is very unique.

Fully automated workplace

The aim of the project was to create a robotic workstation where, without the need for operatorintervention, design structures on the taillights would be created using a laser to replace the existing masking technology. For this purpose, we designed and installed a fully automated compact laser cell for the customer, with final optical inspection using neural networks and OK/NOK part separation with full integration into the parent production system.

At its core is a 6-axis industrial robot that picks up a part on a pallet and moves it under a static laser head, where the laser removes a thin metal layer from the plated plastic structures, in precisely defined 98 areas, with a repeatable accuracy of ±0.03 mm. The laser process is tuned to avoid thermal effects or damage to the substrate material and to maintain all the required optical characteristics without final fogging.

The surfaces are then lighted through, and a neural network camera system mounted on the robot performs a 100% optical quality control. Before handing over the finished part for assembly, the product is blown with ionised air to remove static charge from the surface of the machined layer.

Main benefits

Thanks to this unique laser technology, the customer can realize design patterns on the taillights that were impossible to realize with masking technology. At the same time, the entire process has been considerably accelerated (from 340 s to 110 s), while maintaining the required quality and accuracy to hundredths of a millimetre in areas up to 1700 x 1200 mm². In addition, the implemented technology is waste-free, saving the company additional waste management costs. A significant benefit is also the large reduction in carbon footprint and CO₂ emissions per part produced, which are nowadays very closely monitored production parameters.

Features and benefits of the solution:

• Creating original design structures that cannot be realized with other existing technologies.
• Removing plated layers from plastic parts without masking with high contrast
• Reduction of production of NOK parts
• Achieving high quality layer removal without thermal impact and damage to the base material
• Accuracy of the complete laser machining process to hundredths of a millimetre in areas up to 1700 x 1200 mm²
• Reduction of CO₂ emissions and energy consumption in production, leading to CO₂ neutrality
• Significant acceleration of the entire process from 340 s to 110 s