This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using Laser Engraving in Tissue Embossing Presented by Carl Ingalls, Embossing Technologies Ed Giesler, Giesler Enterprises Inc. CMM International 2003 Conference 1 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Tissue Products With Embossing CMM International 2003 Conference 2 Always embossedNapkins Usually embossedPaper towels Often embossedBath tissue Rarely embossedFacial tissue Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Rotary Embossing Process Schematic CMM International 2003 Conference 3 Paper path Engraved roll Rubber covered roll Rolled product Ingalls & Giesler

Evaluating new embossing patterns. Making steel rolls from laser engraved rolls. Short production runs. Long-term use in production. Very Special Cases. This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International Evaluating new embossing patterns. Making steel rolls from laser engraved rolls. Short production runs. Long-term use in production. Very Special Cases. This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Tissue Embossing Applications for Laser Engraved Rolls – Today CMM International 2003 Conference 4 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Less expensive, on a per engraving basis. Shorter life, requiring more frequent re-engraving. Faster delivery time.Easily damaged – during shipping, handling, and in use. Higher accuracy in positioning the pattern elements on the surface of the roller. Less accurate control of depth, sidewall shape, and curvatures (“radiusing”). Advantages and Disadvantages of Laser Engraving – Compared to Conventional Steel CMM International 2003 Conference 5 continued to next slide … AdvantagesDisadvantages Less expensive, on a per engraving basis. Shorter life, requiring more frequent re-engraving. Faster delivery time. This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International Easily damaged – during shipping, handling, and in use. Higher accuracy in positioning the pattern elements on the surface of the roller. Less accurate control of depth, sidewall shape, and curvatures (“radiusing”). continued to next slide … Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The ability to use more complex patterns. Poorer quality surface finish. Complete digital control of the image, computer to computer, even when engraving large rolls. The technology for copying the contour of an existing surface into a computer is not as accurate. Advantages and Disadvantages, continued CMM International 2003 Conference 6 AdvantagesDisadvantages Complete digital control of the image, computer to computer, even when engraving large rolls. The technology for copying the contour of an existing surface into a computer is not as accurate. The ability to use more complex patterns. Poorer quality surface finish. This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Laser Engraving Process Today CMM International 2003 Conference 7 Start with a smooth steel roll. Cover the roll with a laser-engravable material. Program the laser with the pattern to be engraved. Energize the beam !! Put the roll into the laser machine and start it turning. C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L Engraving is done. Clean the roll, box it, and ship it. Cure the coating, and grind smooth. Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Laser Engraving Technologies: Etch Profiles CMM International 2003 Conference 2D “Square” profile 2-Level Vertical walls C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L D Enhanced “Mesa” profile 2-Level Sloped walls C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L D Any profile Multi-Level Complex contours C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L metallic mask Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference More About Profile Geometry CMM International 2003 Conference 9 An engraved embossing roll C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L A single boss engraved depth A Single Boss Created by Carl Ingalls and Ed Giesler for CMM International 2003 sidewall sidewall angle shoulder radius fillet radius Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Problem of “Nesting” in a Roll of Product CMM International 2003 Conference Nesting band 10 Anti- Nesting band C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference The Problem of “Ridging” in a Roll of Product CMM International 2003 Conference Machine Direction (MD) 11 Extreme MD alignment aligned slanted Slightly slanted from MD Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference R&D Embossing –good for short runs –laser engraved removable sleeves Production Embossing –practical in only very special situations –useful life anywhere between a few hours and several months Embossing with Laser Engraved Cylinders CMM International 2003 Conference 12 R&D Embossing –good for short runs –laser engraved removable sleeves Production Embossing –practical in only very special situations –useful life anywhere between a few hours and several months Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference 2. Put the coated roll into a laser. Using a Laser with Acid to Engrave Steel CMM International 2003 Conference Start with a smooth steel roll. Cover with acid resistant coating. C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L Spray the roll with acid. The acid etches the unprotected areas of steel. continued to next slide … Ingalls & Giesler Burn a pattern thru the coating.

… repeat until desired depth is reached. C R E A T E D B Y C A R L I N G A L L S A N D E D G I E S L E R F O R C M M I N T E R N A T I O N A L This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Using a Laser with Acid to Engrave Steel (cont.) CMM International 2003 Conference Continue with the same roll … 3002 lanoitanretnI MMC rof relseiG dE dna sllagnI lraC yb detaerC add more protective coating laser engrave coating acid etch metal Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Why We Cannot Acid Etch in One Step CMM International 2003 Conference 15 Acid will etch in all directions at once, and can cause undercutting if not controlled by repeated application of the protective coating. Steel base Coating Ingalls & Giesler Pattern put into the coating, either by mechanical pressure or by laser etch. Created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Copying & Multiplying a Pattern: From Tooling Through Production Roll CMM International 2003 Conference 16 Master Roll (optional)Final Production Roll Original Tooling This slide created by Carl Ingalls and Ed Giesler, Sr. for CMM International 2003 Intermediate Tooling copy … that has the pattern already engraved into it. Begin with … Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Stepping a Tool Across a Roll to Multiply the Pattern CMM International 2003 Conference 17 The lower roll must be steel for the acid etch process to work. The upper roll is a tool, which may be conventional or laser engraved. Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Making a Pattern Transfer (Copy) From One Roll to Another CMM International 2003 Conference 18 Start with a roll that is already engraved with the pattern … … and a blank roll that is to be engraved. Cover the blank roll with an acid- resistant wax coating. Bring the rolls together, so that wax is squeezed out at the contact points. Start the rolls turning together, to transfer the pattern to the wax. Bring in an acid bath … to etch away the unprotected steel. Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Acquire customer contacts. Understand embossing applications. Learn required laser size and capability. Learn what other changes are needed. Understand how to prioritize all the above. Acquire customer contacts. Understand embossing applications. Learn required laser size and capability. Learn what other changes are needed. Understand how to prioritize all the above. What’s In It For The Laser Engravers CMM International 2003 Conference 19 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference MATERIALS Find or develop a wear resistant covering that is comparable to chrome plated steel 3D Method to do sophisticated contour engraving QUALITY Improve surface finish ACCURACY Improve dimensional tolerances - (M/S) Challenges for Laser Engravers MATERIALS Find or develop a wear resistant covering that is comparable to chrome plated steel 3D Method to do sophisticated contour engraving QUALITY Improve surface finish ACCURACY Improve dimensional tolerances - (M/S) CMM International 2003 Conference 20 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference PAST Experimental use only (trial rolls). Everyone was Happy PRESENT Making Tooling & Master Rolls, plus trial rolls. Making only a few production rolls. Still mostly OK FUTURE Anything could happen … Proactive and/or Concerned PAST Experimental use only (trial rolls). Everyone was Happy PRESENT Making Tooling & Master Rolls, plus trial rolls. Making only a few production rolls. Still mostly OK FUTURE Anything could happen … Proactive and/or Concerned Reactions from Conventional Engravers CMM International 2003 Conference 21 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Laser engraved rolls are here now. The future depends upon continued developments: –Composition of the surface to be engraved. –Capabilities of the laser engraving machines. –Laser engraving process technology. –Using laser engraved rolls to make steel embossing rolls. –Learning how to reduce the wear on laser engraved embossing rolls. Conclusion Laser engraved rolls are here now. The future depends upon continued developments: –Composition of the surface to be engraved. –Capabilities of the laser engraving machines. –Laser engraving process technology. –Using laser engraved rolls to make steel embossing rolls. –Learning how to reduce the wear on laser engraved embossing rolls. CMM International 2003 Conference 22 Ingalls & Giesler

This slide presentation was created by Carl Ingalls and Ed Giesler for CMM International 2003 Conference Thank You for Your Participation !! We welcome your questions at any time At the CMM Conference By phone By CMM International 2003 Conference 23 Carl Ingalls Ed Giesler Ingalls & Giesler