Adligenswil, Switzerland, May 2021 – Sekisui Alveo, European manufacturer of high-quality polyolefin foams, recently had a cross section of its wide range of foams tested for laser cutting and marking on the eurolaser M-800 laser cutter. The test results confirm excellent suitability for laser cutting of the foams tested. Eurolaser has officially certified the outstanding results achieved with fifteen foams in five Sekisui Alveo product lines.

Engineers at eurolaser conducted the tests at the company’s applications centre in Lüneburg, Germany in January, 2021. The fifteen certified foam samples represent all five of the standard Sekisui Alveo product lines: Alveolit, Alveolen, Alveolux, Alveosoft, and Evalen. The test samples of these foams showed uniform results: excellent suitability for laser cutting and marking.

Excellent suitability for laser processing

The samples tested represent a broad range of densities (expansions from 05 to 36), thicknesses (up to 6mm), additives, pigments, and raw material basis, including PE, PP, and EVA. The testing included laser cutting of precise geometric shapes, laser scoring (kiss-cut), and engraving. Processing precision, speed, and cleanliness were evaluated as performance indicators. The results were outstanding for all fifteen samples tested. Perfectly cut finished edges were consistently and rapidly produced, even when cutting small-radius and angular contours with changes in direction. Laser processing caused no detectable contamination or release of particles onto the foam surface. No additional cleaning or other post-processing treatment (e.g. heat treating of the surface) was required. Performance was equally outstanding for laser marking, scoring, and engraving of the foam samples.

The eurolaser M-800 laser cutter

The machine used for the tests was the eurolaser M-800 laser cutter equipped with a 400-watt laser and an optional automatic shuttle table. Use of the shuttle table does not affect the quality of the cut edge, but it increases productivity and expands the range of materials that can be processed. The eurolaser M-800 features a purge air nozzle that blows any dust that could arise during the cutting process in the suction. Because the cutting area is underlaid with a vacuum, it does not matter whether the foam to be processed is flame-retardant or not.

The M-800 laser cutter can be used in a variety of ways and can process various materials without changing tools. The shuttle table option allows the use of two cutting tables in tandem. While one table is being used for cutting, the other table is used for removing and reloading material, and the tables then change automatically. This maximises efficiency, productivity, and cost effectiveness. eurolaser offers a wide range of optional features for its laser cutters in order to facilitate specific processes. These include a pilot laser, integrable mechanical tools, and modules for labeling, printing, marking or optical recognition. The optional knife and routing tools facilitate the handling of materials that cannot be processed with a laser due to pollutant emissions during cutting (e.g. materials containing PVC).

Advantages of laser cutting

Laser cutting is an ideal cutting method in many cases. Laser cutters are quieter than other types of cutting machines like water-jet cutters or routers. They are also cleaner, because no particles arise, as with mechanical cutting. Besides cleanliness and precision, other advantages include easy handling, no drying phase, time and cost savings in processing, and cutting & engraving on one machine, less tool wear and consistently high cutting quality. Laser cutting is also an advantageous method for converting foam composites incorporating laminated fabric or adhesive strips. Laser cutting has a better sustainability profile than water-jet cutting because of the lower energy consumption and zero water consumption. Eurolaser cutting systems are optimized for an 24/7 use in production.

Tested materials

The following Sekisui Alveo foams were evaluated in the tests and certified by eurolaser: 

• Alveolit TA 3006 - the soft grade
• Alveolit TE 1503 - the special-touch material
• Alveolit TP LPM 2 1503 - for automotive applications
• Alveolen NA 0605 - the hard standard grade
• Alveolen NA 3605 - the packaging grade
• Alveolen NT 2504 - the high-load packaging grade
• Alveolen NP FRG 2005 - the flame retardant grade
• Alveolen NP FRG 2905.5 - the flame retardant soft grade
• Alveolen NEE 2506 - very soft grade
• Alveolux XRE 1005 - the rebound, soft and rubber-touch grade
• Alveolux XSA 1005 - the shock absorbing viscolelastic grade
• Alveolux XA 0605 - the standard fine-cell grade
• Alveolux XE 0605 - the soft fine-cell grade
• Alveosoft SA VM 005 - special soft material with excellent recovery
• EVALEN P - for insole applications

A short film of the laser testing is available online:

https://youtu.be/gVQYyV_1Omc

All the test certificates are available online:

https://www.eurolaser.com/de/referenzen/kooperationen/sekisui-alveo/

A detailed report for all tested materials is available upon request from eurolaser.

Ideal solution for packaging applications

The advantages of laser cutting and marking have made this conversion method a standard procedure in the field of packaging. The laser cutter offers great flexibility in use, allowing any shapes to be easily cut with high precision. Crisp and precise inscriptions and logos can be added to foam inserts used in display boxes for high-quality products. Surface engraving can be done in one step with no need for post-processing.

The German case manufacturer W.AG Funktion & Design GmbH has been using a eurolaser machine for processing Sekisui Alveo foams for over two years. CEO Bertram Göb says the company has been a pioneer in the field of laser cutting rigid PE foams: “We can rely on high-quality results in laser engraving and laser cutting Alveo's foams in our daily operations. In addition to the production of cases, foam processing is an extension of our service and product portfolio."

Advantages for converters

eurolaser’s certified test results are good news for converting companies because they give assurance of achieving desired high-quality results with no need for trial testing. Sekisui Alveo foams and the eurolaser laser cutters are an ideal combination – a proven solution for efficient and precise laser processing of a wide range of high-quality foams. Both Sekisui Alveo and eurolaser will gladly provide assistance or technical support concerning specific projects or applications customers may have.