March 2009 - Gasket Fabricators Association

THE GASKET
FABRICATOR
www.gasketfab.com
Volume 28 Number 1
IN THIS ISSUE
President's Message
Page 1
Origins of the GFA
Pages 2-3
&RPSDQ\3UR¿OHV
Page 3
3UHVV5HOHDVHV
Page 5
New Association
Members
Page 5
*DVNHWV,Q(OHYDWHG
7HPSHUDWXUH6HUYLFH
Pages 6-7
6WHHO5XOH
Pages 7-8
Tightness Parameter
Page 8
TechTeam - New GFA
0HPEHU6HUYLFH
Page 10
Future Meeting
6FKHGXOH
Page 10
Benchmarking Report
Page 10
MARCH 2009
PRESIDENT'S MESSAGE
Clem Foley
Through no fault of our own we are all
in a mess created by a situation or situations
EH\RQGRXUFRQWURO7KHYHU\¿UVWLWHPZH
look at cutting is attending trade shows/
conferences etc. I would strongly suggest
this can be a very unproductive and a short
WHUP JDLQ ZLWKRXW ORRNLQJ DW WKH WHUUL¿F
opportunity these conventions can have for
XVDQGRXU¿UPVZKHWKHUZHDUHVXSSOLHUV
or fabricators. Please hear me out and judge
for yourself.
:KHQWLPHVDUHJRRGZHVKDUHVXFFHVVVWRULHVDQGVXJJHVWLRQVRQKRZ
to improve our sales and bottom line. Now is the time and opportunity to talk to
¿UPVWKDWDUHYHU\PXFKOLNH\RXURZQ¿UPRQKRZWRMXVWSODLQVXUYLYH7KHVH
are the toughest times any one of us has ever seen and it will take a lot of very
hard decisions and ingenuity to get through and continue on.
Our customers are hanging on to their cash for fear of running out and
DVDUHVXOWRXUDFFRXQWVUHFHLYDEOHVDUHVXIIHULQJDIIHFWLQJRXWDELOLW\WRSD\
RXUVXSSOLHUVVWDIIHWF(YHU\RQHLVFDXWLRXVFRQFHUQLQJLQYHQWRU\VRWKHEDOO
FRQWLQXHVWRIDOO,WLVDV\RXDUHIXOO\DZDUHDYLFLRXVF\FOHDQGDV,UHSHDW
VRPHYHU\YHU\WRXJKGHFLVLRQVKDYHWREHPDGHDQGPDGHQRZ
'HFLVLRQVOLNHOHWWLQJVWDIIJRJRLQJWRDKRXUZRUNZHHNSD\
UHGXFWLRQ,ZRQ
WUHSHDWZKDWWKHVHKDUGGHFLVLRQVDUHDV\RXDUHDOODZDUH
RIWKHP7KHUHDUHDOZD\VVRPHQRYHOLGHDVOLNHWKDWRIRQHFRPSDQ\ZKHUH
the owner took no pay for a while and another that found a key man insurance
policy that was no longer important to the company. They cancelled the policy
IRUDVDYLQJRIFORVHWRD\HDUDQGLWKDGDFDVKYDOXHRIVR
that cash went to the bottom line.
We are all in the same boat and can learn from each other's unique and
LQYHQWLYHZD\VWRJHWWKURXJKWKLVVWRUP.HHSLQPLQGWRRWKDWPLVVLQJWKHVH
PHHWLQJVPDNHV\RXDQG\RXU¿UPFRQVSLFXRXVE\\RXUDEVHQFHDQGPD\JLYH
the wrong message to your customers or suppliers attending. It really is not the
time to stay home. Doing this is akin to letting your sales staff go because they
are well paid and you will save a ton of money.
.HHSLQPLQGZHDUHDOOLQWKHVDOHVEXVLQHVV7KLVLVZKDWJRWXVKHUH
and that is what is going to get us through this mess.
Thanks for reading this.
See you all soon.
PAGE 2
THE GASKET FABRICATOR
MARCH 2009
ORIGINS OF THE GFA
1977
,Q $XJXVW RI %RE *HUVFKNH :LVFRQVLQ *DVNHW
DQG 0DQXIDFWXULQJ &RPSDQ\ -RKQ )LW]JHUDOG *DVNHW
(QJLQHHULQJ DQG %LOO :DOWHUV &RRSHU 0DQXIDFWXULQJ
FRQWDFWHG %UHQW )DUEHU DW 0XOWL6HUYLFH 0DQDJHPHQW
&RPSDQ\00&RLQ3KLODGHOSKLDDERXWVWDUWLQJD*DVNHW
&XWWHUV$VVRFLDWLRQ%REZKRZDVDPHPEHURIWKH)OXLG
6HDOLQJ$VVRFLDWLRQDOVRPDQDJHGE\00&RDVNHG%UHQW
if he would help set up this new association.
1978
,Q)HEUXDU\DOHWWHUZDVVHQWWRWHQJDVNHWFXWWHUVLQYLWLQJ
WKHP WR DQ RUJDQL]DWLRQDO PHHWLQJ WR GLVFXVV VWDUWLQJ D
new association
$Q 2UJDQL]DWLRQDO *URXS RI WKHVH WHQ FRPSDQLHV PHW
RQ$SULODWWKH2¶+DUH+LOWRQLQ&KLFDJR$
%RDUG RI 'LUHFWRUV 3UR7HP ZDV HOHFWHG DQG D OHWWHU
of invitation was sent to a list of prospective members.
7HQWDWLYHTXDOL¿FDWLRQVLQFOXGHGDQDQQXDOVDOHVYROXPH
RIPLOOLRQRILQKRXVHGLHFXWJDVNHWVDQGDPLQLPXP
RIHPSOR\HHV7KH'LUHFWRUVZHUH
3DXO%UXFH$XWRPDWHG*DVNHW
-RKQ)LW]JHUDOG*DVNHW(QJLQHHULQJ&R
:DUUHQ'XFORQ([FHOVLRU,QF
%RE*HUVFKNH:LVFRQVLQ*DVNHW0IJ
%LOO:DOWHUV&RRSHU0IJ&R
$O(GZDUGV4XDOLW\*DVNHW0IJ&R
$UJ\OH-DFNVRQ+RRVLHU*DVNHW&RUS
$FFXUDWH)HOW*DVNHW
$SSDODFKLDQ*DVNHW&R
$XWRPDWHG*DVNHW&RPSDQ\
%HDYHULWH3URGXFWV
&KLFDJR:LOFR[
&LQFLQQDWL*DVNHW3DFNLQJ0IJ
Cooper Mfg. Co.
-0&UDQ]&R
A.T. Doyle Company
(YHUVHDO*DVNHW6WDPSLQJ
([FHOVLRU,QF
*DUORFN,QF
*DVNHW(QJLQHHULQJ&RPSDQ\
*ROGHQ6WDWH6WDPSLQJ*DVNHW
*RVKHQ'LH&XWWLQJ
*UDQG+DYHQ*DVNHW&RPSDQ\
+LJEHH5XEEHU&RPSDQ\
+RRVLHU*DVNHW
0DULQH3HWUROHXP6XSSO\
0XHOOHU%HOWLQJ6SHFLDOW\&R
2ULHQWDO*DVNHW3DFNLQJ
4XDOLW\*DVNHW0IJ
5XVVHOO*DVNHW&RPSDQ\
7RP0F*XDQH,QGXVWULHV
8QWLHG*DVNHW&RUS
:LVFRQVLQ*DVNHW0IJ
,Q2FWREHUVHYHQDGGLWLRQDODVVRFLDWHPHPEHUVZHUH
HOHFWHGWRPHPEHUVKLSDVIROORZV
1LFROHW,QF
6KHOOHU*OREH&RUSRUDWLRQ
Tiegler Corp.
West American Rubber
+HUPDQ6FKZDEH
)HGHUDO0RJHO
-RKQV0DQYLOOH
1979
2Q-DQXDU\WKH2UJDQL]DWLRQ0HHWLQJRI*DVNHW
)DEULFDWRUV$VVRFLDWLRQ ZDV KHOG DW WKH 2¶+DUH +LOWRQ
LQ &KLFDJR $Q DQQXDO EXGJHW RI ZDV VHW DQG
directors were elected. The directors included those listed
DERYHSOXV-DPHV&UDQ],,RI-0&UDQ]&RDQG0(
7KRPSVRQRI2ULHQWDO*DVNHW3DFNLQJ'XHVZHUHVHW
DW7KHSURSRVHGE\ODZVZHUHDPHQGHGWRGHFUHDVH
WKHQXPEHURIHPSOR\HHVUHTXLUHGIURPWR7KH¿UVW
RI¿FHUVHOHFWHGZHUH
1981
,Q 6HSWHPEHU 6WHYH 6KDLPDQ WRRN RYHU DV *)$ /HJDO
Counsel.
3UHVLGHQW
9LFH3UHVLGHQW 6HFUHWDU\7UHDVXUHU
1987
,Q0DUFK%UHQW)DUEHUUHWLUHGDQG%RE(FNHUWRRNRYHU
DV([HFXWLYH'LUHFWRU
(/³%RE´*HUVFKNH
$UJ\OH-DFNVRQ
-RKQ-)LW]JHUDOG
,Q 0D\ WKH ¿UVW $QQXDO 0HHWLQJ ZDV KHOG DW
,QQLVEURRN5HVRUWLQ7DUSRQ6SULQJV)/,WZDVGHFLGHGWR
DFFHSWDVVRFLDWHPHPEHUVKLSVDQG*DUORFNZDVDGPLWWHGWR
PHPEHUVKLS$FFRUGLQJWRWKH0D\*)$'LUHFWRU\
LQLWLDOPHPEHUVRIWKHDVVRFLDWLRQZHUH
2002
,Q)HEUXDU\3HWHU/DQFHFDPHRQERDUGDV$GPLQLVWUDWLYH
Director.
,Q6HSWHPEHUWKH¿UVW6XSSOLHU([SRZDVKHOG
Continued on Page 3...
MARCH 2009
THE GASKET FABRICATOR
ORIGINS OF THE GFA
(Continued from Page 2...)
2006
,Q0DUFKWKH*)$SUHVHQWHGWKHLQDXJXUDO*DVNHWLQJ
&RQYHUWLQJ([SRLQ2UODQGR)ORULGDGUDZLQJRYHU¿YH
KXQGUHGDWWHQGHHVDQGQLQHW\VHYHQH[KLELWRUVWRDWUDGH
VKRZGHYRWHGH[FOXVLYHO\WRWKHJDVNHWLQJDQGFRQYHUWLQJ
industries.
PAGE 3
'LH0DVWHUVLVDVXEVLGLDU\RI6HUYLFH3DN*URXS
DPLQRULW\RZQHGFRPSDQ\IRXQGHGLQ6HUYLFH3DN
*URXSPDQXIDFWXUHVIROGLQJFDUWRQVGLHFXWSDSHUERDUG
SURGXFWV DQG SRLQWRISXUFKDVH GLVSOD\V )RU PRUH
LQIRUPDWLRQFRQWDFW.HYLQ+DUIVWDW
2008
Marian Inc. is a global leader in providing precision
$ VHFRQG *DVNHWLQJ&RQYHUWLQJ ([SR ZDV KHOG LQ
GLHFXWFRPSRQHQWSDUWVIRUFXVWRPHUVLQWKHFRQVXPHU
2UODQGRLQ$SULOPDWFKLQJWKHVXFFHVVRIWKH¿UVW([SR
and receiving overwhelmingly positive feedback from HOHFWURQLFV DXWRPRWLYH DQG PHGLFDO LQGXVWULHV :LWK
RYHUVTXDUHIHHWRISURGXFWLRQVSDFHZRUOGZLGH
DWWHQGHHVDQGH[KLELWRUV
DQGVWDWHRIWKHDUWPDQXIDFWXULQJWHFKQRORJLHV0DULDQ
7KH*)$JUHZWRDUHFRUGRIPHPEHUV)DEULFDWRUV HQJLQHHUVZRUNFORVHO\ZLWKFXVWRPHUVWRVROYHFRPSOH[
manufacturing and assembly problems.
DQG6XSSOLHUV
0DULDQ¶VUHVSRQVLYHDSSURDFKLQGHSWKPDWHULDO
2009
NQRZOHGJH LQQRYDWLYH PDQXIDFWXULQJ FDSDELOLWLHV
*)$FHOHEUDWHVWK$QQLYHUVDU\
and high standards for quality all add up to provide
our customers with the best component solutions in
WKH LQGXVWU\ )RU PRUH LQIRUPDWLRQ DERXW 0DULDQ¶V
DSSOLFDWLRQVDQGFDSDELOLWLHVSOHDVHFRQWDFWXVDWZZZ
PDULDQLQFFRPRUDW
COMPANY PROFILES
'LH0DVWHUV KDV EHHQ SURYLGLQJ QDWLRQZLGH
service of the highest quality steel rule and clicker dies
IRURYHU\HDUVIURPRXU0LGZHVWORFDWLRQLQ/HQH[D
Kansas.
Our inventories and vendors allow us to stock
D ZLGH YDULHW\ RI ERDUG LQFOXGLQJ 0DSOH 89 &RDWHG
%LUFK /H[DQ DQG 6\QWKHWLF &RPSRVLWH DOORZLQJ XV WR
SURYLGHDEDFNLQJVSHFL¿FWRHDFKW\SHRIUXOHQHFHVVDU\
IRUSUHFLVLRQGLHFXWWLQJPXOWLSOHUHNQLIHVDQGWKHWLJKWHVW
tolerances in the industry.
2XU VWHHO UXOH UDQJHV IURP ± SW LQ D YDVW
assortment of bevels and perforations designed for
optimum die life. Our blade edges are available in both
VKDYHGHGJHSDSHUERDUGVDQGJURXQGHGJHV\QWKHWLFV
%URZVHRXUZHEVLWHZZZGLHPDVWHUVFRPIRU
RXUFDSDELOLWLHVWHFKQRORJ\DQGFRQWDFWV9LHZRXU3')
FRQ¿UPDWLRQVWKDWFDQEHHPDLOHGRUID[HGIRUHDFKVWHHO
UXOHGLHRUGHUDQGDVNXVIRULPPHGLDWHRQOLQHWUDFNLQJ
RIGLHVWKDWDUHVKLSSHGYLD836RU)HG([
/HW'LH0DVWHUVEH\RXUVRXUFHIRUNQRZOHGJH
information and quality. Our database allows us to monitor
the dies as they proceed from layout to laser burning to
automatic rule bending. We also provide immediate
response for quoting and scheduling insuring your budget
DQGVFKHGXOHZLOOEHRQWLPHDOOWKHWLPH
2YHU WKH SDVW ¿IW\ \HDUV 36& )DEULFDWLQJ KDV
EHFRPH UHFRJQL]HG DV D PDUNHW OHDGHU IRU SURYLGLQJ
H[FHOOHQFHLQWKHIDEULFDWLRQLQGXVWU\36&)DEULFDWLQJ
LVDPXOWLSODQWJOREDOSURYLGHURIQRQPHWDOOLFSURGXFWV
VHUYLQJ 2ULJLQDO (TXLSPHQW 0DQXIDFWXUHUV LQ WKH
$SSOLDQFH+9$&$XWRPRWLYH7UDQVSRUWDWLRQ0HGLFDO
2I¿FH)XUQLWXUHDQG*HQHUDO,QGXVWULDOPDUNHWV
Major product lines include cellular and solid
SRO\XUHWKDQHV SRO\ROHILQV UXEEHU 39& SURGXFWV
¿EHUJODVV LQVXODWLRQV FRWWRQ DQG SRO\PHU DFRXVWLFDO
LQVXODWLRQV HOHFWULFDO LQVXODWLRQV DQG SDSHU SURGXFWV
)DEULFDWLRQFDSDELOLWLHVLQFOXGHSUHFLVLRQÀDWDQGURWDU\
GLH FXWWLQJ VOLWWLQJ ODPLQDWLRQ ZDWHU MHW DQG SUR¿OH
FXWWLQJDQGDVVHPEO\3URGXFWLRQLVFRPSOLPHQWHGE\
LQKRXVHGHVLJQDQGGHYHORSPHQWWRROLQJGHYHORSPHQW
laboratory and quality control services.
:LWKWRWDOFXVWRPHUVDWLVIDFWLRQDVRXUJRDOZH
look forward to the opportunity to serve your company
DQGSURYLGH6DYLQJVWKURXJK4XDOLW\DQG6HUYLFH
)RU PRUH LQIRUPDWLRQ SOHDVH FRQWDFW 0LNH
0DWWLQJO\ 1DWLRQDO 6DOHV DQG 0DUNHWLQJ 0DQDJHU DW
RUHPDLODWPLNHP#SVFRIN\FRP
PAGE 4
THE GASKET FABRICATOR
MARCH 2009
630.889.8655
www.itwformex.com
Flame Retardant Materials
SCORE IT! FOLD IT! BEND IT!
High Quality Electrical Insulation available in sheets, rolls, and panels.
UL 94V-0 flammability. Extremely low moisture absorption.
Die Cut
Laser
Water Jet
Heat Form
Machine
Thermoform
Easily Printed, Laminated, Welded. Cost Effective.
DEPEND ON IT!
MARCH 2009
THE GASKET FABRICATOR
PAGE 5
PRESS RELEASES
Jacobs & Thompson Inc.
Acquires Globaltex
-DFREV 7KRPSVRQ ,QF D 7RURQWR EDVHG
division of RCR International and one of the largest
IRDP FRQYHUWHUV LQ 1RUWK $PHULFD DQQRXQFHG LW KDV
DFTXLUHGWKHFXVWRPHUEDVHDQGHTXLSPHQWRI*OREDOWH[
/WG:LQGVRU2QWDULR
7KLVDFTXLVLWLRQDOORZV-DFREV7KRPSVRQWR
SURYLGHLWVH[LVWLQJFXVWRPHUEDVHZLWKDGGLWLRQDOSURGXFW
offerings and opens new market sectors for the company.
*OREDOWH[/WGZDVIRXQGHGLQDQGVSHFLDOL]HGLQ
laminating and die cut goods for the automotive industry.
)RXQGHGLQDQGKHDGTXDUWHUHGLQ7RURQWR
-DFREV 7KRPSVRQ ,QF LV RQH RI WKH ODUJHVW IRDP
FRQYHUWHUV LQ 1RUWK$PHULFD VHUYLQJ WKH DXWRPRWLYH
DSSOLDQFHZLQGRZDQGGRRUDQGJHQHUDOPDQXIDFWXULQJ
VHFWRUV)RUPRUHLQIRUPDWLRQFDOORUYLVLW
www.foamparts.ca.
Rogers Issues New
Selection Guide For Its
Bisco® Silicone Materials
5RJHUV &RUSRUDWLRQ KDV LVVXHG D QHZ SDJH
0DWHULDO6HOHFWLRQ*XLGHIRULWV%,6&2Š6LOLFRQHPDWHULDO
7KHVHPDWHULDOVZKLFKDUHRIIHUHGLQFHOOXODUVROLGDQG
VSHFLDOW\ JUDGHV DUH XVHG LQ D ZLGH UDQJH RI PDUNHWV
from transportation and communications to electronics
and high intensity lighting. Applications include gaskets
DQGVHDOVKLJKWHPSHUDWXUH3&%WKHUPDOLQVXODWLRQDQG
EDWWHU\VKLHOGVDXWRPRWLYHKHDWVKLHOGVDQGYLEUDWLRQDQG
acoustic mitigation pads.
7KHQHZ%,6&26HOHFWLRQ*XLGHLQFOXGHVSURGXFW
samples and tips for materials selection based on market
DSSOLFDWLRQV7KHUHDUHVSHFL¿FDWLRQWDEOHVIRUFHOOXODUDQG
VROLG JUDGH VLOLFRQHV OLVWLQJ W\SLFDO SK\VLFDO SURSHUWLHV
ÀDPPDELOLW\DQGRXWJDVVLQJWHPSHUDWXUHUHVLVWDQFHDQG
electrical/thermal properties.
Additional tables provide acoustic and thermal
performance values for specialty silicones; thickness
tolerances for cellular standard and solid standard; width
WROHUDQFHIRUDOOWKUHHJUDGHVDHURVSDFHJOREDODQGJHQHUDO
LQGXVWU\VSHFL¿FDWLRQVDQGSURGXFWDYDLODELOLW\
5RJHUV¶ %,6&2 6LOLFRQHV DUH UHVLVWDQW WR
WHPSHUDWXUHH[WUHPHV89DQGR]RQHDQGDUHH[WUHPHO\
UHVLVWDQWWRPHFKDQLFDOIDWLJXH7KH\DOVRH[KLELWH[FHOOHQW
FRPSUHVVLRQVHWDQGFUHHSUHVLVWDQFH$OO%,6&26LOLFRQHV
FDUU\WKHPRVWVWULQJHQW8/ÀDPHUDWLQJVDYDLODEOH
7R REWDLQ D FRS\ RI WKH QHZ %,6&2 6LOLFRQH
0DWHULDOVHOHFWLRQ*XLGHFDOO)RUSURGXFW
RUGHUV FDOO )RU IXUWKHU LQIRUPDWLRQ RQ
%,6&26LOLFRQHPDWHULDOVIURP5RJHUVYLVLW
www.rogerscorporation.com/hpf/bisco.
Venture Tape Corp.
Completes Acquisition of
Compac Corp.’s Pressure
Sensitive Adhesives Assets
9HQWXUH7DSH&RUSDVXEVLGLDU\RI0DQQRXQFHG
WKDWLWKDVFRPSOHWHGLWVDFTXLVLWLRQRI&RPSDF&RUS¶V
SUHVVXUHVHQVLWLYHDGKHVLYH36$WDSHDVVHWVIURP/DPWHF
Corp. Terms of the transaction were not disclosed.
$OO&RPSDF36$WDSHSURGXFWVZKLFKDUHXVHGIRU
WKHLQVXODWLRQLQGXVWULDODQGKHDWLQJYHQWLODWLRQDQGDLU
FRQGLWLRQLQJ+9$&PDUNHWVQRZZLOOEHVXSSOLHGIURP
Venture Tape Corp. Venture Tape manufactures a broad
UDQJHRIWDSHVXVHGLQFRQVWUXFWLRQRLODQGJDV+9$&
HOHFWURQLFVDHURVSDFHPDULQHDQGDSSOLDQFHPDUNHWV
)RURYHU\HDUV&RPSDFKDVEHHQDQLQGXVWU\
leader in supplying insulation facings and tapes to
GLVWULEXWRUVDURXQGWKHZRUOG&RPSDF¶VIXOOOLQHRIWDSHV
ZLOOFRQWLQXHWREHDYDLODEOHDVZHOODVFXVWRPHUVXSSRUW
7RYLHZ&RPSDF¶VSURGXFWVYLVLWWKHFRPSDQ\¶VZHEVLWH
DWZZZFRPSDFFRPRUIRUPRUHLQIRUPDWLRQFDOO(G6RUH
SURGXFWPDQDJHUDW
NEW ASSOCIATION
MEMBERS
Fabricator
IDENTCO International Corporation
,QJOHVLGH,/
www.identco.com
PSC Fabricating Co.
/RXLVYLOOH.<
www.pscofky.com
United Seal and Rubber Co., Inc.
$WODQWD*$
www.unitedseal.com
Suppliers
Service Pak Group / Die-Masters
3DFL¿F02
ZZZ'LH0DVWHUVFRP
NOVA Chemicals, Inc.
0RRQ7RZQVKLS3$
www.novachemicals.com
PAGE 6
THE GASKET FABRICATOR
MARCH 2009
TECHNICAL ARTICLES
Submitted By: Larry Pyle, LFP Technologies
Gaskets In Elevated-Temperature Service
Of all the environmental parameters affecting
the behavior of gasketed joints is that of elevated
temperature. Thermal cycles can also cause even more
GLVWUHVV%HORZDUHOLVWHGVHYHUDORIWKHHIIHFWV
NOTE$QDUWLFOHDERXWWKH7*$FDQEHIRXQG
LQWKH:LQWHULVVXHRIThe Gasket Fabricator.
Physical Degradation of the Gasket
+LJK WHPSHUDWXUHV FDQ GHJUDGH D JDVNHW LQ
VHYHUDOZD\VFKDQJLQJVXFKWKLQJVDVWHQVLOHVWUHQJWK
UHVLOLHQFH PRGXOXV RI HODVWLFLW\ DQG WKH DELOLW\ WR
VXSSRUW FRPSUHVVLYH ORDGV )LJXUH EHORZ VKRZV
D JHQHUDO GHFUHDVH LQ PD[LPXP VHUYLFH VWUHVV IRU D
variety of materials.
)LJXUH:HLJKWYV7HPSHUDWXUH
)LJXUH*DVNHW6WUHVVYV7HPSHUDWXUH
2QO\ÀH[LEOHJUDSKLWHLQWKLVH[DPSOHUHPDLQV
unaffected by the temperatures shown here. A solid
PHWDORUHPERVVHGPHWDOJDVNHWQRWVKRZQZRXOGEH
similarly unaffected. Curves for the other materials
represent the points at which the combination of stress
and temperature plotted would create irreversible
distortion and/or decomposition of the gasket.
Many of the proposed asbestos substitute
FRPSRVLWH PDWHULDOV IDLO E\ WKHUPDO GHJUDGDWLRQ WKH
clays or other organics used as binders turn to powder
ZKHQ VXEMHFWHG WR H[WUHPHO\ KLJK WHPSHUDWXUHV $
relatively simple method for determining the effect of
elevated temperature on materials is through the use of
D 7*$ 7KHUPR*UDYLPHWULF DQDO\VLV 7KH H[DPSOH
VKRZQLQ¿JXUHLQGLFDWHVWKDWWKHJDVNHWVPDGHIURP
this material would degradate at temperature above
ƒ&
Creep and Relaxation
(OHYDWHGWHPSHUDWXUHFDQLQFUHDVHWKHDPRXQW
RIFUHHSRUUHOD[DWLRQDJDVNHWH[SHULHQFHVXQGHUORDG
7KHUHSRUWHGURRPWHPSHUDWXUHUHOD[DWLRQXQGHUOLJKW
ORDGVRIDFRPSUHVVHGDVEHVWRVJDVNHWLVDERXW
&UHHSV DQG UHOD[DWLRQV RI WKH VDPH PDWHULDO XQGHU
VLPLODU ORDGV KDYH EHHQ UHSRUWHG DV KLJK DV DW
DSSUR[LPDWHO\ ƒ) 5HVXOWV DUH VLPLODU IRU RWKHU
materials especially those with organic binders and
ZLWKDQ\¿OOHUVZKLFKGHJUDGHDWHOHYDWHGWHPSHUDWXUH
$QH[DPSOHRIVXFKD¿OOHUZRXOGEHFHOOXORVH
Thermal Expansion or Contraction
2QHVKRW GLIIHUHQWLDO WKHUPDO H[SDQVLRQ
or contraction can increase the load on a gasket.
This phenomenon can raise or lower gasket stress.
6HDODELOLW\FDQEHLPSURYHGRUGHJUDGHGGHSHQGLQJRQ
whether or not gasket stress is increased of decreased.
Thermal Cycles
0RUHFRPSOH[DQGGLI¿FXOWWRSUHGLFWFKDQJHV
can occur if repeated thermal cycles are involved. Two
W\SHVRIEHKDYLRUDUHUHSUHVHQWHGLQ¿JXUH
Continued on Page 7...
MARCH 2009
THE GASKET FABRICATOR
PAGE 7
Gaskets In ElevatedTemperature Service
(Continued from Page 6...)
)LJXUH*DVNHW6WUHVVYV*DVNHW'HÀHFWLRQ
Steel Rule
)LJXUH/RDGYV'HIRUPDWLRQ
The effect of the thermal cycling as a gasket
is called ratcheting. Racheting can be seen in two
IRUPV VWUHVV UDWFKHWLQJ DQG GHÀHFWLRQ UDWFKHWLQJ
7KLVUDWFKHWLQJLVFDXVHGE\DFRPELQDWLRQRIIDFWRUV
LQFOXGLQJ WLPHGHSHQGHQW SODVWLFLW\ FUHHS WLPH
LQGHSHQGHQW SODVWLFLW\ K\VWHUHVLV DQG WKH JHQHUDO
QRQOLQHDULW\LQWKHVWUHVVVWUDLQUHVSRQVHRIWKHJDVNHW
,IWKHORDGFRQWDFWVWUHVVLVF\FOHGEHWZHHQ
FRQVWDQWPD[LPXPDQGPLQLPXPYDOYHVWKHGHÀHFWLRQ
RI WKH JDVNHW LV FDOOHG ³UDWFKHWHG´ ZLWK WKH JDVNHW
becoming thinner with each cycle. The thickness will
HYHQWXDOO\VWDELOL]H7KLVFRQGLWLRQLVLOOXVWUDWHGLQWKH
top curve.
,I WKH JDVNHW LV F\FOHG EHWZHHQ PD[LPXP
DQG PLQLPXP GHÀHFWLRQV WKH VWUHVVHV RI WKH JDVNHW
SURJUHVVLYHO\GHFUHDVHVDVVKRZQLQWKHVHFRQGFXUYH
,IWKHJDVNHWIDLOVWRVWDELOL]HDWDUHVLGXDOORDGYDOYH
DERYHWKDWZKLFKLVUHTXLUHGWRPDLQWDLQWKHVHDOWKH
gasket will leak.
0RVW JDVNHWV LQ ¿HOG DSSOLFDWLRQV ZLOO
H[SHULHQFH D FRPELQDWLRQ RI VWUHVV UDWFKHWLQJ DQG
GHÀHFWLRQUDWFKHWLQJDVLOOXVWUDWHGLQ¿JXUH
Steel rule dies have been used as the primary
FXWWLQJPHWKRGIRUVRIWSURGXFWVLQFOXGLQJJDVNHWVIRU
decades. Not intended for the cutting of close tolerance
SDUWVEXWDFFXUDWHHQRXJKIRUPRVW6WHHOUXOHGLHVDUH
UHODWLYHO\LQH[SHQVLYHDQGHDV\WRPDNHEXWGRUHTXLUH
constant maintenance to maintain a clean and accurate
cut.
7KHGLHVFRQVLVWRIDÀDWEDVHZKLFKLVXVXDOO\
PDGH RXW RI KLJKJUDGH KLJKGHQVLW\ SO\ZRRG 7KH
plywood is usually composed out of hardwoods such
as maple and is free from voids or other imperfections.
Some special dies may require aluminum or steel
VXEVWUDWHV 7KH GLHPDNHU XVHV D VSHFLDO EDQG VDZ
MLJVDZ RU ODVHU FXWWHU WR SUHFLVHO\ FXW SRVLWLRQHG VOLWV
into the substrate. The steel rule itself is essentially
DQ HORQJDWHG UD]RU EODGH PDGH RI KDUGHQHG VWHHO7KH
GLHPDNHU FXWV DQG EHQGV WKH VWHHO UXOH DQG SRVLWLRQV
LWLQWRWKHVOLWVLQWKHVXEVWUDWH7KH¿QDOVWHSLQWKHGLH
making process involves the addition of ejection rubber.
Rubber pads are adhered to the substrate to help eject
the material after it is cut. This rubber is available in
various durometers.
The steel rule itself is available in a variety of
IRUPVDQGIRUDYDULHW\RIFXWV
Cutting rule
Perforating rule
Creasing rule
Rotary rule
Combination cut and crease rule
Wave rule
=LSSHURU7HDU(GJHUXOH
The tables on the following page show the
DYDLODELOLW\RIWKHPRVWFRPPRQFXWWLQJUXOH<RXFDQ
VHHWKDWWKH\DUHDYDLODEOHLQDZLGHYDULHW\RIWKLFNQHVV
KDUGQHVVEHYHOVDQGKHLJKWV
Continued on Page 8...
THE GASKET FABRICATOR
PAGE 8
Steel Rule
(Continued from Page 7...)
MARCH 2009
$WLJKWQHVVSDUDPHWHURIZRXOGPHDQWKDWLW
WDNHVDFRQWDLQHGSUHVVXUHRIDWPRVSKHUHVSVL
RU0SDWRFUHDWHDWRWDOOHDNUDWHRIDERXWPJVHF
IURPDJDVNHWKDYLQJDLQFKRXWHUGLDPHWHU
1RWHWKDWWKHWLJKWQHVVSDUDPHWHULVH[SUHVVHG
in terms of mass leak rate rather than volumetric leak
rate. This allows the lumping of test data representing a
YDULHW\RIWHVWÀXLGVVRPHJDVHRXVVRPHOLTXLG
)LJXUHEHORZLVDORJORJSORWRIJDVNHWVWUHVV
YVWLJKWQHVVSDUDPHWHUIRUDVSLUDOZRXQGJDVNHWZLWK
ÀH[LEOHJUDSKLWH¿OOHUDQGVWDLQOHVVVWHHOZLQGLQJV7KH
WHVWÀXLGZDVKHOLXP
Tightness Parameter
In the last issue of The Gasket FabricatorDQ
DUWLFOHZDVZULWWHQDERXWWKH0DQG<IDFWRUVIRXQGLQ
WKH$60(%RLOHU&RGH,QWKDWDUWLFOHLWZDVLQGLFDWHG
that there were newer concepts for designing gaskets
within the industry governed by the code.
The Tightness Parameter
Investigators discovered by testing gaskets
under a variety of conditions and with a variety of
FRQWDLQHGÀXLGVWKDWWHVWGDWDFRXOGEHVWE\VXPPDUL]HG
E\XVHRIDGLPHQVLRQOHVVSDUDPHWHUFDOOHGD³WLJKWQHVV
SDUDPHWHU´GH¿QHGDVIROORZV
Where
73 33>/50/UP'W@D
73 WKHWLJKWQHVVSDUDPHWHUGLPHQVLRQOHVV
3 WKHFRQWDLQHGSUHVVXUHSVLRUN3D
3 UHIHUHQFHDWPRVSKHULFSUHVVXUHSVL
RUN3D
/UP PDVVOHDNUDWHOEKULQPJVHFPP
/50 UHIHUHQFHPDVVOHDGUDWHZKLFKLV
NH\HGWRDQRUPDOL]HGUHIHUHQFH
JDVNHWRILQFKRXWVLGHGLDPHWHU
D H[SHULPHQWDOO\GHWHUPLQHGH[SRQHQWHJ
LIWKHFRQWDLQHGÀXLGLVDJDVLILWLV
a liquid)
'W JDVNHW2'LQPP
NEWSLETTER
The Gasket FabricatorLVSXEOLVKHGE\WKH*DVNHW)DEULFDWRUV
Association and distributed to all members and prospective
PHPEHUVRI*)$
3UHVLGHQW&OHP)ROH\
9LFH3UHVLGHQW6WHYH+DQVRQ
([HFXWLYH'LUHFWRU5REHUW+(FNHU
$GPLQLVWUDWLYH'LUHFWRU1HZVOHWWHU(GLWRU3HWHU/DQFH
&RPPXQLFDWLRQV&RPPLWWHH&KDLU&KULV%UDQG
Members are encouraged to contribute articles and items of
interest to the Gasket Fabricator. All contributions should
EHDGGUHVVHGWR([HFXWLYH'LUHFWRU*)$2OG(DJOH
6FKRRO5RDG6XLWH:D\QH3$3KRQH
)D[ +RPH 3DJH ZZZ
JDVNHWIDEFRP(PDLOLQIR#JDVNHWIDEFRP
Articles appearing in this publication may not be
reproduced without written consent from the Association.
Articles appearing in the Gasket Fabricator are the
views of the authors and not necessarily those of the
Association.
‹&RS\ULJKW*DVNHW)DEULFDWRUV$VVRFLDWLRQ
MARCH 2009
THE GASKET FABRICATOR
PAGE 9
PAGE 10
THE GASKET FABRICATOR
NEW GFA MEMBER
SERVICE
7KH*)$LQFROODERUDWLRQZLWKWKH,QWHUQDWLRQDO
$VVRFLDWLRQ RI 'LHFXWWLQJ DQG 'LHPDNLQJ ,$'' LV
offering a new service to members. TechTeam™ is a
GHGLFDWHGDQGH[SHULHQFHGWHDPRILQGXVWU\SURIHVVLRQDOV
who stand ready to assist you. Their mission is to quickly
UHVHDUFKDQGDQVZHU*)$0HPEHUV
WHFKQLFDOGLHFXWWLQJ
DQG GLHPDNLQJ TXHVWLRQV LQ DQ XQELDVHG FRQ¿GHQWLDO
FXUUHQWDQGGLUHFWPDQQHU
6LQFHWKHVHUYLFHZDVODXQFKHGIRU*)$PHPEHUV
LQ2FWREHUWKH7HDPKDVKDQGOHGTXHVWLRQVIURP
PHPEHUVZKRKDYHLQWXUQEHHQDEOHWRDVVLVWQRWRQO\
WKHLURZQEXVLQHVVHVEXWDOVRWKHLUFXVWRPHUVZKRKDYH
DVNHGTXHVWLRQVRIWKHP4XHVWLRQVDVNHGKDYHUDQJHG
IURPGLHZHDUZKHQFXWWLQJ¿EHUERDUGWRGLHOLIHDQG
SDUW TXDOLW\ LQ FXWWLQJ VSHFLDOW\ JDVNHWV WR VWDQGDUG
tolerances in cutting a variety of different materials.
8VLQJ WKH 7HFK7HDPΠZLOO VDYH \RX WLPH
PRQH\DQGPDWHULDOVDQGFDQPDNH\RXORRNOLNHDKHUR
WR\RXUFXVWRPHURUFRPSDQ\$OVRWKHUHLVWKHEHQH¿W
of having several eyes looking at the same problem and
offering a variety of timely and helpful solutions to your
toughest problems.
&RQWDFWLQJWKH7HDPLVHDV\6XEPLWDTXHVWLRQ
WUDFN LW DQG IROORZ XS XVLQJ DQ HDV\ ZHEIRUP LQ WKH
0HPEHUV 2QO\ DUHD RI WKH *)$ ZHEVLWH 7KH ¿UVW
GFA FUTURE MEETING
SCHEDULE
Fall 2009 Semi-Annual Meeting
6HSWHPEHU
$UL]RQD*UDQG5HVRUW
3KRHQL[$=
Gasketing/Converting Expo '10
0DUFK
+LOWRQ2UODQGR
2UODQGR)/
MARCH 2009
UHVSRQVH WR TXHVWLRQV JHQHUDOO\ FRPHV ZLWKLQ WKH ¿UVW
KRXUVRIDTXHVWLRQEHLQJDVNHGVRPHWLPHVZLWKLQ
WKH¿UVWKRXU
*)$ 0HPEHUV FDQ DFFHVV WKH VHUYLFH E\
FOLFNLQJ RQ 0HPEHUV 2QO\ RQ WKH *)$¶V KRPH SDJH
ZZZJDVNHWIDEFRP 0HPEHUV ZKR KDYH IRUJRWWHQ
WKHLUXVHUQDPHDQGSDVVZRUGVKRXOGFRQWDFWWKH*)$
RI¿FHDWRULQIR#JDVNHWIDEFRP
BENCHMARKING
REPORT
%HORZDUHWKHUHVXOWVIURPWKH%HQFKPDUNLQJ
%HORZDUHWKHUHVXOWVIURPWKH%HQFKPDUNLQJ
6XUYH\ZKLFKZDVXQGHUWDNHQWRJLYH*)$PHPEHUV
6XUYH\ZKLFKZDVXQGHUWDNHQWRJLYH*)$PHPEHUV
a thumbnail sketch of how other members are fairing
at this time.
:HKDGRXWRI)DEULFDWRUUHVSRQVHV
0RVW5HFHQW4XDUWHU6DOHV&RPSDUHGWR
0RVW5HFHQW4XDUWHU6DOHV&RPSDUHGWR
3UHYLRXV4XDUWHU
83 '2:1
6$0(
&XUUHQW 4XDUWHU 6DOHV 3URMHFWLRQ
&RPSDUHGWR/DVW4XDUWHU
83 '2:1
6$0(
:HKDGRXWRI6XSSOLHUUHVSRQVHV
0RVW5HFHQW4XDUWHU6DOHV&RPSDUHGWR
0RVW5HFHQW4XDUWHU6DOHV&RPSDUHGWR
3UHYLRXV4XDUWHU
83 '2:1
6$0(
&XUUHQW 4XDUWHU 6DOHV 3URMHFWLRQ
&RPSDUHGWR/DVW4XDUWHU
83 '2:1
6$0(
MARCH 2009
THE GASKET FABRICATOR
PAGE 11
ACRYLIC & RUBBER BASED
GASKET ATTACHMENT SOLUTIONS
800-343-1076
www.venturetape.com
High Performance
Sealing Solutions
MicroPore® technology outperforms
conventional gasket materials in a wide range
of automotive and industrial applications.
Value Grades provide assured availability,
fast delivery and application testing.
Ê£‡nä䇙-/ÊUÊÜÜÜ°Ãi>ˆ˜vœ°Vœ“Ê
PAGE 12
THE GASKET FABRICATOR
MARCH 2009
Thermoseal
Solutions For Every Application
NEW
Performance Technology Group
Multi-Layer Technology Grades & Advantage Roll Goods
developed for OEM and Aftermarket industries
KLINGERSIL compressed gasketing
Soft-chem expanded PTFE gasketing
KLINGERtop-chem PTFE gasketing
Sealex PTFE joint sealant
800-990-SEAL · www.thermosealinc.com
Material performance
around the globe >>
% LOW DENSITY
SILICONE FOAM
% CLOSED CELL
SILICONE SPONGE
% SOLID SILICONE
In continuous rolls,
extrusions or molded parts
This white paper was created by Preco Inc., at the request of the Technical Committee of the Gasket Fabricators
Association (GFA). Its purpose is to provide information to Association members on recent developments in laser
technology that are used in the gasket manufacturing process. Preco, Inc. is a U.S. based company that provides die
cutting and laser services and equipment throughout the world.
This paper details recent advances in laser technology that are enabling gasket manufacturers to handle a wider
variety of materials than before and to bid short run and intricate jobs that were previously uneconomical to quote.
New types of lasers, laser delivery methods and laser platforms used to process a variety of non-metallic materials
for the gasket industry are the focus of this article.
In addition, operating costs, operator training, safety, and maintenance issues surrounding the use of lasers are
included for consideration. Case studies feature how the introduction of lasers has dramatically changed the business
of several manufacturers. Finally, the paper provides answers to questions frequently asked by manufacturers who
are considering getting started with lasers – either by contracting with a laser job shop or purchasing a system for
in-house production.
Laser Basics for Die Cutting Fabricators
Historically lasers have not been the “go to” device in the gasket industry because of speed, cost,
and technology limitations. But with new developments in lasers, especially in laser control, now
is a good time to update your laser knowledge base.
Laser System Development
Lasers began to make an appearance in industry in the 1970s
for cutting and engraving. The 1980s brought the advent
of laser cutting as part of CNC processes utilizing stepper
controls. But what still limited the extensive use of lasers
on many jobs was material processing expertise and quality
control.
Along with the advancements in personal computer
technology in the 1990s, the use of lasers in manufacturing
became much more prevalent. The power of PCs enabled
the integration of computer aided design (CAD) into laser
systems. It became feasible to digitally design and implement
a pattern through the same process.
A drawback at this time was that many systems had
proprietary software and operating systems. However,
most systems in the field today have standardized to the
Microsoft Windows™ operating system, which allows for
greater application flexibility and easier system upgrades
and maintenance.
Another recent and significant development in lasers is
system modularity. New “hybrid” laser modules can be
added to rotary die cutting lines. These modular lasers are
designed to work in a wide variety of production lines.
Adding laser technology to rotary die cutting greatly
enhances speed by combining what had historically been
two processes. Also, there is greater flexibility in the types
of materials that can be processed with a hybrid system as
both macro and micro cuts can be made.
The word, LASER is derived from Light Amplification
by Stimulated Emission of Radiation. It’s an energy
source, much like a light bulb. A laser works by
transmitting a light beam – of one color in the spectrum
– in a concentrated focused path.
A working laser was first demonstrated in 1960 at the
Hughes Research Laboratory. It was originally thought
of as a solution in search of a problem. Now, the
greatest use of lasers is in optical storage devices such
as compact disc and DVD players.
Lasers then, Lasers now
Through the years, improvements in laser technology have
produced steady increases in output power. Gases, dyes,
crystals and chemical compounds are now used in common
lasers to produce a variety of wavelength bands to meet
different application and material processing needs.
Lasers are used in medicine for a variety of procedures
including bloodless surgery, eye treatment, dentistry, and
kidney stone reduction. Lasers are also found in a myriad
of defense applications such as weapon guidance, target
marking, and electro-optical countermeasures. Lasers are
even used for packaging applications that require scoring
for easy opening, or perforating for breathability.
One of the main advantages of lasers is the flexibility it
gives companies in taking on a variety of jobs – especially
small or specialty work. Lasers eliminate the need for tool
and die fabrication, as well as the need to maintain and store
dies. Laser control systems use digital CAD files to aid in
just-in-time manufacturing. Repeat orders can be retrieved
and duplicated in minutes.
New Developments In Laser Technology
Lasers are especially useful with applications where it is
beneficial to keep the cutting tool from coming in contact
with the processed material. Non-contact with the cutting
surface means that materials with adhesive surfaces will
not become gummed up during the cutting process. Also,
a laser cut is a thermo process that can vaporize fine
material; therefore, leaving less fine particulate matter in
the process.
New types of lasers
• Economical, low maintenance sealed lasers with up to
1000 watts of power.
• Higher powered UV lasers that produce better edge
quality and the capability to produce finer cut features.
This means cleaner and faster ablation (or removal) of
certain materials.
• Alternative wavelengths that offer the ability to tailor
the wavelength to a specific material type to improve
cutting speeds and cut quality. For example, reduction
of heat affected zones (HAZ), smoke accumulation, and
charring.
Faster cutting without sacrificing accuracy
• High speed, high performance, motion systems that
use fiber optics and faster, more accurate 2 or 3-axis
galvanometers.
Integration options with material handling systems
• Modular lasers that can be added directly on to the die
cutting process line. These lasers typically have a small
footprint and can be adapted for use in prototyping all
the way through full production. Many use galvanometer technology that allows process flexibility
including kiss cutting, perforating, scoring, slitting and
through cutting.
What Lasers Do Well
While die cutting still remains a highly economical means
to produce large runs using some materials, here are some
laser advantages to consider when you are looking at your
processes and system operations (See 1A).
Basic Types of Lasers Used with Non-metallic Materials
Today, most Fiber and Nd:YAG type lasers are used in metals
processing operations. Typically, ultra violet (UV) and Fiber
lasers use diode pumped solid state (DPSS) technology. New
lasers are being developed that use alternative wavelengths
that will expand the capabilities of laser processing.
Lasers used in the non-metal gasket industry can generally
be divided by the wavelength required. Most use CO2 gas
or ultraviolet wavelengths to process materials such as
polypropylene, polyesters, and polyimides.
Advantages (1A)
System
• Window PC controller
• Digital Processing from a CAD file
• Jobs stored in files for quick retrieval
• Low operating & maintenance costs
Process
• Instant results from testing
• Always sharp
• Wide range of power
• Non-contact
Product
• Seals edge of materials
• Drops slugs out
• Small & intricate geometry processing
• Consistent cut width and depth
Unique Options
• Multiple cutting/function head options
• Laser capabilities easy to upgrade
• Integration into existing production lines
• XY-Theta Vision Registration
Laser Characteristics
CO2
Nd:YAG
Fiber
UV
9.27 – 10.6 —m
1064 nm
1075 – 1090 nm
355 nm
.003 – 0.10
.001 – .002
.001 – .002
.0005 – .001
10 – 1000
10 – 1000
10 – 10,000
3 – 20
10,000 – 20,000 hrs.
(sealed laser)
5+ years
10+ years
5+ years
Non-metalic and Metals
Metals or Metal Films
Metals or Metal Films
Polyimide, Ceramic,
Copper
Wavelengths
Spot Sizes (inches)
Power Ranges (watts)
Life Span
Best Materials
Laser Delivery
Depending upon the material and product used in the
process, a laser beam delivery option needs to be made.
Delivery of the laser beam is typically accomplished in one
of the following ways:
1. Fixed Beam – XY table moves the material
2. Flying Optic – XY moves beam over stationary platform
3. Galvanometer – Steered or directed beam with or
without any material motion.
4. Robotic Motion
Laser Platforms
What are galvos, XY systems, XY tables, and flying
optics? These are all types of laser platforms designed to
handle different types of materials. Lasers and optics are
continuously improving providing the capability to process
faster, cleaner and more accurate cuts.
Some platforms are designed to primary handle sheet
stock materials, some web stock materials, and some both.
Further, laser beam options impact the spot size on cutting
speeds and power requirements. The following is a simple
comparison of platform types and performance:
Platform
Position Accuracy
Relative Cost
Stepper
Low
Low
Belt Drive
Low
Low
Rack and Pinion
Medium
Medium
Ball Screw
High
High
Servo (Rotary)
High
High
Servo (Linear Motors)
High
High
even discoloration on the material. There are times however,
with adhesives for example, that it can be an advantage as
HAZ will cauterize the edge and not allow the adhesive to
flow, thus providing better edge quality.
Kerf Width & Taper - Kerf is the amount of material the
laser removes. Taper is the difference between the kerf at
the top of the cut and the bottom of the cut. Ideally, most
materials are processed so that the kerf is equal all the way
through the material. This set up can be achieved by setting
the focal point correctly.
Focal Length - A lens is used to focus the laser beam to a
spot. A short focal length creates a tight spot with higher
power density.
Assist Gases – Typically, when cutting nonmetals, assist
gasses are not used. However, the two most commonly used
gasses are compressed air and nitrogen.
Spot Size, Power Density & Impact on Cutting Speed –
A fast cut requires the use of a tight spot with high power
density. Another consideration is desired edge quality. For
example, acrylic can be cut fast, but in order to create a fire
polished edge it must be cut at a slower speed.
Special Lenses (Telecentric Lenses) - Telecentric lenses
are used to help correct the angle of the beam in the entire
field of view. These lenses orient the beam perpendicular
to material when galvonometers are used in the process.
Telecentric lenses are beneficial in minimizing taper and
when cutting geometry is close to the edge of the field of
view. However, telecentric lenses can only be used for small
cutting areas.
Important Issues for Achieving a Quality Laser Cut
HAZ – Heat Affected Zone is typically considered
undesirable because this condition can leave burrs, a ridge or
Thermal Distortion – Thermal distortion is an undesirable
situation where heat causes material to ripple or warp. It is
similar to the condition found with HAZ.
The following inset piece is an example of laser processing using 0.075mm polyester and acrylic adhesive. This
application utilized laser technology along with a tiling technique to compensate for the inherent screen print stretch.
A screen printed sheet was sectioned into quadrants to improve on cut-to-screen registration.
Entire sheet:
1 minute processing time
(manual load and unload)
Total cutouts including
perimeter: 900
Raw Material Sheet
With 12 Parts
Four 9 inch cutting
quadrants
Camera registration
marks. Two per quadrant
for XY and rotation
registration.
Critical Laser Benefits
• Producing a sealed adhesive edge to prevent
reflow, tackiness and re-closure (1)
• Producing narrow slots that do not
re-attach or close in the laminated
structure (2)
• Producing small holes through adhesive
layers that remain open after placement
and throughout product life (3)
• Producing small features that are
dimensionally stable and easily drop out
of the matrix when stripped (5)
Total Processing Time:
2 seconds
Cutting Accuracy:
±0.10mm (±0.004 in.)
CO2 Laser Power:
200 watts
PET Film Thickness
0.075 mm
0.003 in
1. Via Separation
0.500 mm
0.019 in
2. Slot Thickness
0.100 mm
0.004 in
3. Via Diameter
0.280 mm
0.011 in
4. Square Separation
1.500 mm
0.059 in
5. Hole Diameter
2.470 mm
0.097 in
±0.100 mm
±0.004 in
6. Overall Registration
to Print
Total cut outs including perimeter: 75
Stop/Start Marks - Stop and start marks result from the
point where a laser enters the material to where the cutting
process ends. If the geometry of the cut is such that the line
comes back to meet the initial start mark, there may be some
overlap. This condition may be more evident on some types
of materials.
quality, important when processing these materials. Also,
laser cutting leaves little or no burrs, debris, or strands on
the material edges. Further, applications are not limited to
just cutting — welding, heat treating, and marking are also
common uses for laser technology.
Other issues to consider for control of cut quality include:
•
•
•
•
•
•
Accuracy
Taper/angle
Power level
Productivity rate
Edge quality
Distortion
Advantages of Using Lasers in the Gasket Industry
Cost -With the selection of the right laser and platform, a
gasket manufacturing process can be set up with no tooling
costs and gives the operator the ability to cut micro features
not typically possible with standard male/female and steel
rule dies or etching tooling.
The use of lasers has other advantages over die cutting
in processing because there are no die setup costs, no die
maintenance, and no storage costs. If a project is recalled
into production, a digital program can quickly be retrieved.
Materials Flexibility - Abrasive, adhesive, cork, paper,
rubber, silicone, steel, and many types of polymer
materials are all prime candidates for processing using
laser technology. Laser cutting produces exceptional edge
Materials Class
Description
The table below provides information about laser cutting
of various materials typically found in the gasket industry.
However, the linear speed listed is based on a single system
and is not intended to indicate optimal parameters for any
specific material.
Flexibility in the Types of Jobs - When a job requires a
quick setup or a pattern change, the use of lasers cannot
be beat. Similarly, if the project requires a great deal of
vision alignment and registration, laser technology allows
the operator to register parts before processing and align
the cut pattern registration features – either printed or mold
features.
Material Type
Thickness
(mm)
Power Req.
(watts)
Linear Speed
(mm/sec)
Adhesives
Pressure sensitive adhesive (PSA)
w/single or double liners – liner may
be paper or polymer
3M467
3M7961
3M4930
0.34
0.50
0.75
70
100
100
300 – 400
225 – 275
80 – 120
Cork
Cork sheets, may be “light” or “dark” and
may be bonded with rubber elastomer for
gaskets.
Sheet
1.9
50
25 – 40
Foam
Material may be rubber (elastomer) or
expanded polymers (e.g., PU, PE, or PET).
Foam may be classified as either “open
cell” or “closed cell.”
Closed Cell
Open Cell
5.0
10.0
100
50
100 – 120
60 – 80
Paper
Card (poster) stock material, Coated
packaging materials, or liner materials
Paper
0.35
50
300 – 400
PC - Polymer
(Polycarbonate)
Polycarbonate
PC
0.5
100
150 – 250
PC - Plymer
(Polyethylene)
Polyethylene
PE
0.6
100
100 – 120
Rubber
May be natural latex rubbers or synthetic
rubbers such as Neoprene
Rubber
1.0
100
100 – 160
Wood
Woods
Die, Maple
16.0
240
4–8
Reduced Time to Proficiency for Operators - With
the wide acceptance of Microsoft Windows™ computer
operating systems, the training of laser systems operators
has been greatly simplified in the past several years. The
typical steps in training a laser operator are simply to:
• Generate a program file (CAD or CNC)
• Create a laser parameter and recipe storage file
• Execute the program file
Once an operator has mastered these fundamental steps,
new jobs can be rapidly set up on the laser system.
Laser Safety and Maintenance - There are some safety
and maintenance issues that must be taken into account
when using a laser. First, safety issues include awareness
that when working some materials like PVC, noxious gases
are emitted during the cutting process. Common solutions
to safety and quality issues include the installation of air
flow handling equipment and masking devices.
For the most part, the newest generation of lasers are sealed
systems that require little maintenance. Typical failure points
in a laser system are usually the external optics, especially
when they are not properly maintained. To prevent laser optic
failure, routine maintenance includes periodic cleaning.
A Real Life Job – Done with Lasers
As an example of how lasers expanded the versatility and
profitability of one company, a Canadian medical device
manufacturer recently enlisted the help of a laser contract
firm to complete a job creating polyester gaskets with
adhesive backing. The application required making a small
cut feature in the gasket lamination.
The existing manufacturing process used by the company
allowed adhesive to flow back into the cut opening, creating
unacceptable parts. The laser system used by the contract
firm proved to be the only reliable method of processing by
providing a cut that both vaporized and sealed the edge. The
laser process eliminated the adhesive reflow.
With this success, the company retained the laser contractor
to do short production runs. Eventually, the product required
production runs up to 100,000 parts per month. The company
then found it to be economical to purchase a laser system
of their own. Overall, using the laser process enabled the
company to get a precision, high quality part quickly and
reliably to market.
How to Get Started with Lasers
If your company has been strictly a die cutting operation,
you don’t necessarily need to “no quote” jobs that require
laser cutting. Here are a few steps to get you started:
Pick a Knowledgeable, Established Supplier - There
are many companies that specialize in laser cutting to
whom you can sub-contract to enhance your capabilities.
As in hiring any subcontractor, it is important to do a little
research on the laser job shop’s performance history and
equipment capabilities. Places to start looking for a reliable,
experienced laser contractor in your area include:
•
•
•
•
Industry networking
Internet searches
Trade shows
Trade journals
Here are some questions that can be asked of a prospective
laser contractor:
1. What platforms are available? Check that they satisfy
your manufacturing requirements. For example, can the
platform handle flat sheet or roll stock?
2. What tolerances can be held?
3. Are samples of cut quality and speed for specific
materials available?
4. What types of digital file formats can be accommodated?
For example, which CAD and CNC file types are
accepted?
Again, a little research will go a long way. It is important
to ask a potential laser contractor about their expertise and
equipment in applications similar to your business. Checking
a prospective laser job shop’s references about service and
response times is also important.
Cost Considerations - At a certain point, the amount of
jobs that you choose to bid may reach a volume that will
justify the purchase of your own laser system. There are a
wide range of costs for laser systems depending upon the
complexity of the job needs:
System Type
Cost Range
Applications
Lower Power
Systems
$30,000 to $50,000
Sample production
Standard Commercial
$100,000 to $350,000
Power Systems
Special Commercial
Systems
$400,000 +
Non-metallic job
production
Variety of
applications
How to Find or Train Laser Technicians – In many
cases, the best place to find a good laser technician is from
within your existing group of die cutting operators. Senior
employees already have a good sense of overall shop floor
practices and typically can be trained to work with the
digital files required to process materials with a laser.
How Much Does It Cost to Run A Laser System?
The laser system uses a variety of support systems based
on the type of material being cut. In a typical application
not all of the sub-systems are used simultaneously but
are presented here for a “worst” case scenario. The
example is for a 200 – 400 watt sealed laser, but does
not include overhead or depreciation of the system.
Main system: Laser System
• 208 Volt, 3 phase, 45 Amp, consumes ~9KW/Hr.
Therefore, electrical for main system is ~$0.60 per
hour based on a $0.065 KW cost.
Support systems:
• Compressed Air (if required): 10 CFH at $0.003/CF.
Therefore, compressed air is ~$0.030/Hr cost.
• Vacuum Blower (if required): 3 HP blower at
~2KW/Hr. Therefore, vacuum blower cost is
~$0.135 per hour based on a $0.065 KW cost.
• Chiller: 208 Volt, 3 phase, 30 Amp consumes
~6KW/Hr. Therefore, electrical for chiller is
~ $0.40 per hour based on a $0.065 KW cost.
• Nitrogen (occasionally required): 10 CFH at
$0.0072/CF. Therefore, Nitrogen cost is ~ $0.072
per hour.
Labor: (Based on Midwest US production rates)
• Production Labor at $ 16.00 per hour.
Total Operating Cost:
• Main System:
$0.60 per hour.
• Support systems:
$0.637 per hour
• Production Labor: $16.00 per hour
Grand Total:
$17.237 per hour
However, if you choose to hire a dedicated technician a good
starting point would be schools offering laser/electro-optics
programs, such as Texas State Technical College Waco,
www.waco.tstc.edu; Indian Hills Community College,
www.indianhills.edu; or Idaho State University, www.isu.
edu; to name a few. Other suitable technical backgrounds to
consider are machining and programming.
Laser Resources – A great reference guide about lasers
is the Laser Institute of America Guide to Laser Cutting.
This book is available through the Laser Institute’s website:
www.laserinstitute.org or by calling 1-800-345-2737.
Several periodic journals can also be recommended:
• Industrial Laser Solutions; www.industrial-lasers.com
• Laser Focus World; www.laserfocusworld.com
• Photonics; www.photonics.com
Growing A Laser Processing Business
One of the nations largest laser job shops, also happens
to be one of the oldest of its kind, dating back to 1978.
The business model was quite unique, and remains in tact
to this day. Leveraging CNC machine design skills, the
company positioned itself to provide both laser contract
manufacturing services, using flexible laser work stations
built and maintained in house, and/or provide turn-key
industrial laser equipment to be installed at a customer’s
site.
The initial primary focus of the companies’ contract
manufacturing was in the area of laser engraving of wood
and plastics. What started as a three person company
operating a single CO2 laser in the basement of the owner’s
house, transitioned to several lasers in a pole shed cutting a
variety of metal and non-metal components.
Today, the company has expanded in several key ways.
Now more than 40 laser work stations process a variety of
materials for the metals and converting markets. These lasers
work stations vary in both power and wavelength to match
specific processing needs. The company has also invested
heavily in an applications development staff through the
years to perform research and development to provide a
continuous stream of leading edge laser technology to be
used in new contract work, or the continued sale of laser
equipment.
An additional strategy the company has utilized is to pursue
a diverse mix of both laser applications and markets.
Current markets include alternative energy, electronic thin
film, packaging, medical, aerospace, automotive, precision
industrial gaskets, heavy off road, and more. Technical,
quality, and production staff are strategically organized
by target market, and the overall business mix allows the
company to hedge against industrial or economic downturns,
and remain healthy and stable.
Why Not Use a Laser to Get the Job Done?
The use of lasers can greatly add to the types of jobs that
a gasket manufacturer can tackle. While die cutting may
still be the most economical means to produce certain
products, laser technology now provides manufacturers with
tremendous process flexibility and the ability to work with
more materials. Further, lasers are an economical means to
complete intricate, high quality jobs.
Contact: Jason Thoen or Kurt Hatella
Please identify yourself as a GFA member
Preco, Inc., Somerset, Wisconsin
800.775.2737 www.precoinc.com