Energy efficient laser processing technologies for packaging manufacturing

Overview

This solution offers energy-efficient laser processing technologies designed to reduce production energy consumption and physical waste in packaging manufacturing. By replacing legacy laser systems (such as CO2 and Nd:YAG, which can be as low as 5% efficient) with modern diode and fiber lasers achieving 60 to 70% wall plug efficiency, manufacturers can significantly lower energy costs. These advanced lasers can be tuned to maximize energy absorption for specific packaging materials, while delivering high repeatability and accuracy. The technology also enables new processing capabilities not possible with traditional methods, including wear-resistant cladding and additive manufacturing of dies with integrated cooling channels.

Technical specifications

Key capabilities and features:

• Energy-efficient laser joining processes that reduce production energy consumption
• Additive manufacturing processes for tooling and packaging-related components
• Lasers tunable to specific packaging materials for optimized energy absorption
• High repeatability and accuracy enabling robust process windows that minimize out-of-spec parts
• Advanced control, characterization, and in-process monitoring of laser processes
• In-process defect detection and advanced material performance control
• Capability for wear-resistant cladding applications
• Additive manufacturing of dies with integrated cooling channels

Workforce development differentiator:

The lab is actively training laser process engineers and collaborating with trade schools to build the future workforce pipeline, addressing the mass retirement of the current on-the-job trained workforce.

Technology readiness level

The proposed engagement begins with travel to the partner's production facilities to identify major production pain points, followed by a five-month experimental proof-of-concept phase with regular virtual update meetings, and concludes with delivery of a prototype, report, and presentation. This staged approach allows validation of the technology against real production challenges before scaling.