High-speed laser cutting of superposed thermoplastic films: thermal modeling and process characterization

Common thermoplastic films used in the packaging industry have a thickness lower than 100 μm, and present low absorption to CO₂ laser radiation. This characteristic renders the use of cutting parameters, predicted by models developed for thicker thermoplastics inappropriate. In addition, the usual procedures involve the use of an assisting gas, responsible for removing the melted material, which, when processing thin films, induces changes in position in the material. A new theoretical model describing the temperature distribution on thin thermoplastic material during laser cutting was later developed. The heat conduction was solved analytically by the Green function method and heating and cooling thermal stress evolution was taken into consideration. The laser beam diameter over the samples provides the possibility of obtaining two cut operations: a simple cut, on beam focus, and a cut with welding, defocusing the beam. Engineering parameters predicted by the model were applied to cutting superposed high- and low-density polyethylene and polypropylene samples, transparent and white, with thicknesses between 10 and 100 μm, and experimentally validated.Proper modeling and the introduction of a reflective substrate under the samples allowed the improvement of process efficiency and the achievement of cutting operations up to 20 m s⁻¹, and cut with welding up to 14 m s⁻¹; an order of magnitude of improvement on industrial speeds previously attained for this operation.