Laser engraving ceramic mesh roller requires a high level of precision to ensure the quality of the roller. In this guide, we have put an ideal processing process of ceramic laser engraving mesh roller. Here are the main 7 steps:
Start with adjusting the mesh roller diameter. Whether new or old roller, make sure that you have ground it until the diameter is approximately 0.5mm smaller than the specific diameters.
The surface of the mesh roller requires good sandblasting so that the strength combining the base roller and coating is improved. At the same time, the bottom layer of the roller should be getting its corrosion resistance improved.
The coat the ceramic layer with chromium oxide using the plasma spraying method. The thickness of the coat should be within a range of 0.3 to 0.5mm. The coating porosity should be less than 1%, especially when the mesh roller contains a high number of wires.
Grind the ceramic coating using the diamond grinding wheel until you get the correct size and outer diameter. Then polish the surface until you have achieved the mirror condition and at the same time ensure the thickness of the mesh roller ceramic coating is above 300μm. Now the mesh roller is ready for laser engraving.
Start the engraving process using a computer controlled laser engraving machine to carve cells depending on the provided specifications. The number of lines, graphics and mesh depth are three crucial factors when engraving. The ceramic coating at the mesh wall and the net wall made from the thermal spray method will, after laser engraving and remelt treatment, produce a denser, harder, and smooth state for better ink transfer.
Polish the engraved mesh roller to mirror state as well as confirm and adjust the volume of the mesh cells. The polishing serves several things, including reducing the friction between the mesh roller, doctor blade and the embossing roller. Reduction in friction will also reduce the wear of the whole cylinder setup.
The last step is using ultrasonic cleaning to restore the shape, depth and volume of the cells. You should also check all the parameters again before starting with printing.
Laser-Engraved Mesh Shape
The laser beam works by engraving tiny etchings or cells on the roller’s ceramic coating. Because of the hot laser beam, these cells form by melting and evaporating the ceramic coating. The resulting shape is usually semi-circular.
The surface of the cell and the cavity shape of the engraved shape forms a spiral shape, honeycomb shape, and a diamond shape, while the shape of the mesh is melted ceramic cells. However, for good quality, the number of lines, shape and angle of the cells should be the same always. That is how you maintain a stable quality of the ceramic mesh roller.