Automating the UDI laser marking process

TLM Laser’s Andy Toms looks at combining robotics with the laser marking process to achieve flexibility within a UDI compliance marking environment.

In order to comply with UDI regulations, a permanent UDI code must be applied to a wide range of medical devices, surgical instruments, and implants. Laser marking has become the prime technology for these marking applications, due to the ability of the laser to mark a diverse selection of materials and the consistent high quality associated with the process.

With ever increasing numbers of items requiring compliance marking, manufacturers are seeking to automate the process wherever possible. Where products are being manufactured within a production line environment, the laser marking system can be incorporated as an integral part of the line. However, for other applications, where there may be a high product mix, or where the marking operation is carried out offline, a more flexible solution is required if the process is to be automated.

The concept of robot machine loading is already well established within high volume manufacturing processes, such as those associated with the automotive sector. These systems ensure high levels of productivity whilst delivering the quality and consistency required by the sector.

The principles and objectives of using the same robotic systems, but combined with laser marking technology, as opposed to CNC machine tools, are exactly the same. With the robot tasked with part handling, transfer, loading and unloading, consistent cycle times will be achieved, guaranteeing the highest levels of productivity. In addition, any parts deemed reject by the laser marking system will be reliably segregated from the good parts, ensuring 100% quality.

TLM’s laser marking technology partner Foba Laser has demonstrated the benefits of automating the laser marking process through a collaboration with Add’n Solutions, a German laser marking service provider, and Fruitcore Robotics. The company was looking for an automatic loading system for its M2000-P laser marking machine, which is used to mark surgical instruments. The primary challenge was the large variety of parts to be marked in small to medium batch sizes. This meant that the system would need to be highly flexible, whilst eliminating lengthy set-up times or modifications to the robot gripper. In addition, the system had to be interfaced to the marking workstation and fully integrated into the process with corresponding process documentation and subsequent machine validation.”

The solution to handling the large variety of parts to be marked, lies in the concept of transferring the surgical instruments on trays to Foba’s M2000-P, as opposed to individually. This eliminates the need for gripper changes or modifications between product or batch variants. With the special tray gripper concept developed, Foba was then involved in setting up the interface to the M-Series and its integration into the marking cell.

A safety enclosure with two access points, a service door and hatch for loading, was designed and the processing procedure defined:

• Instruments are placed on a tray and loaded to a service trolley.
• The 6-axis robot takes a tray from the trolley and loads the M2000-P.
• Within the laser marking station, all parts are checked automatically for part integrity and position.
• The marking content is automatically aligned relative to the part position on the tray and the instruments are marked exactly at the position required.
• The robot then removes the tray with the marked parts and places it back in its original slot in the service trolley.

This system demonstrates how innovative thinking, combined with latest generation technologies, can deliver a series of benefits for the end user. Once primed with the service trolley and trays, this cell will run unmanned ensuring that all parts are not only checked prior to marking, but that the marks are validated post marking before the parts are removed from the cell. The concept of having parts placed in a tray makes it possible for the cell to process multiple part types in small or medium batch sizes.”

TLM Laser is the UK and Ireland distributer for Foba Laser and as a business, TLM has built up a comprehensive portfolio of laser processing technologies. These are supported by ancillary equipment ranging from laser safety eyewear, extraction systems and right through to complete laser safe enclosures, designed and built around the specific application. Add to this the company’s hard-won expertise in applying lasers for cutting, welding, marking, and cleaning applications and potential users of laser technology can leverage from a truly holistic approach to laser system integration.

Visit the TLM Laser website for more information