Custom Etch Inc.

Large Laser Changes the Texture of Automotive Molding
Custom Etch Inc, a 35-person shop in New Castle, Pennsylvania,
has specialized in chemical etching since 1982.
However, in 2011, the shop made a bold move to significantly
expand its capabilities beyond chemical etching and invested
in advanced 5-axis laser-texturing systems.
Fast-forward to the present, and Custom Etch now currently
holds the distinction of being the first U.S. shop to own
one of the industry’s largest laser texturing systems. With
a working envelope big enough to park a full-size car, this
recently added system has driven a significant increase in
the company’s automotive business.
After only a month of testing and training on the large
machine, the shop began using it for production work. The
new system is expected to increase revenue 15 percent in
2014 and Don Melonio Jr., vice president of Custom Etch,
expects that number to increase to 25 percent in the following
year. He explained that the need for such a massive
machine grew out of the desire of automakers to texture interior
components that were previously grained using laser
textured foils. These foils were then wrapped onto master
models used to create tooling. This is an expensive and
time-consuming process and not without its flaws.
“What the laser allows automakers to do is choose textures
that prior to this technology were impossible with traditional
machined tooling,” said Melonio. “So now with laser texturing,
they can add aesthetics where it was previously impossible.
And, because you’re taking the labor component out
of the texturing, you’re also reducing time to market. Laser
texturing of large components can result in significant time
savings versus chemical etching, while cost remains virtually
the same.”
Installed in a new, temperature-controlled building, Custom
Etch’s LASER 4000 5Ax laser texturing system from GF
Machining Solutions features a capacity of over 13 feet by
nine feet by four feet. And since workpieces sit on the floor
for processing, the machine’s weight capacity is limited only
by Custom Etch’s overhead crane capacity. For automotive
customers, that means oversize molds for components
such as bumpers and fascias, instrument and door panels,
central consoles, airbag covers and much more – including
whole interiors – can be laser textured.
The huge system joins the shop’s initial LASER 1000 5Ax
and LASER 1200 5Ax machines, also from GF Machining
Solutions. And all three machines complement the shop’s
chemical etching processes. The smaller lasers handle
parts to 11.8 inches on a side and 27.5 inches on a side. And
a GF Machining Solutions-supplied System 3R pallet system
further enhances their productivity with lights-out operating
capability.
Like the smaller systems, the LASER 4000 5Ax features a
standard programmable tilting laser head, high-resolution
cameras with integrated illumination for fine positioning,
integrated touch probes and dust exhausts, a central lubrication
system and various lenses.
The texturing process begins with a digital bitmap/grayscale
file created in Photoshop or derived from a natural surface
by reverse engineering via a 3D scanner. System software
then merges a virtual workpiece with a virtual texture, and
shops can then preview the final design. With the pattern
loaded, the laser removes material in, for instance 10 to 150
layers, to impart the texture pattern.
The Custom Etch building that houses the large system has
a 25-ton crane and machine foundations three-feet thick.
The concrete floor has internal heating to control the temperature
of mold tooling, regardless of the outside temperature.
Two 20-ton air conditioning units keep the building at a
constant 69 degrees all year around.
“Once the LASER 4000 5Ax was here, we started to make
contact with automotive companies,” recalled Melonio. “The
initial response was, ‘Great, but what does it cost versus
traditional etching?’ And we were able to answer, ‘It doesn’t
cost any more than chemical texturing, and here are all the
benefits versus chemical texturing.’”