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Engraving is the process of rotating a cutting tool in a motorized spindle, which is moved through the material to produce a groove at a specific depth and in the same geometry and width as the cutter tip. It is commonly used on flexible plastic engraving stock to make items such as name badges, key tags, signage and awards. It can also be used on brass, aluminum and acrylic when deeper cuts are required than those achieved by burnishing.

Engraving Cutters & Diamonds

The tools used for rotary engraving are generally referred to as “cutters.” Most engraving cutters are “half-round” tools which means the blank is split or halved on centre producing a “single-lip” tool which is one of having only one cutting edge.

The majority of the engraving machines used in the awards and engraving industry have spindles that use “top-loading” cutters. These are cutters that are inserted into the spindle from the top and are typically held in place by means of a threaded knob. This arrangement allows for easy cutter adjustments and changes. Top-loading cutters are most commonly available in 1/8”, 11/64”, 1/4”, 4mm, and 6mm shank diameters. Cutter lengths vary to accommodate machine spindles and accessories (burnishing attachments, vacuum chip removers, etc.).

Cutter Tip Chart

Diamond Drag (Scratch) Engraving

This type of engraving uses a non-rotating tool that has a “cone-shaped” diamond tip. The tip is pressed into the substrate and dragged across the surface, leaving an impression.

Pluses:

(a) This is the fastest form of engraving
(b) Allows for very fine, detailed engraving
(c) It is the least expensive form of engraving
(d) It is very quiet and does not require a motor
(e) It is the easiest form of engraving and is visually appealing
(f) Can engrave a wide-variety of objects

The process is frequently referred to as “diamond engraving,” “scratch engraving,” or “diamond drag” with the latter probably being the preferred terminology.

Diamond drag engraving can be performed on virtually all metals and in some applications, glass and plastics. In the awards industry, it is typically used as a quick, easy, and inexpensive method of engraving the pre-finished brass and aluminium plates on trophies and plaques. On colour plates, the diamond penetrates the coating and exposes the bare metal; a gold colour on the brass and silver on the aluminium. On material that has a clear coating, the engraving can be blackened with an oxidizing solution to add contrast.

This material is available in a wide variety of colors.

Traffolyte, sometimes spelled Traffolite, was a brand name for multi-layered phenolic plastic sheets suitable for engraving. The material is made up of three layers, the outer layers being engraved to expose the contrasting core.

Traffolyte, is sometimes referred also as Industrial Laminates, generally refer to a class of insulating materials produced by impregnating fibrous webs of materials with the thermosetting resins; then fusing the multiple layers together under high temperature and pressure. The result is infusible laminate structure having a versatile combination of electrical, mechanical and chemical properties.

Available Size

1200mm x 600mm x 3mm, 1200mm x 600mm x 2mm, 1200mm x 600mm x 1.5mm

Colors Available

Black/White/Black, Blue/White/Blue, White/Black/White, Green/White/Green, Red/White/Red, Dark Blue/White/Dark Blue

Material Specification

Cellulose paper made from kraft pulp and high alfa wood pulp is used depending on the type of paper and also the type of resin that is employed, these paper based laminates are classified by ISI into five mechanical grade of the laminate. P1, P2, P3, P4 & P5. P5 is the highest electrical grade of the laminate and P1 the mechanical grade of the laminate. From P1 to P5 the electrical property increases and the mechanical property slightly decreases. The material is weather proof and water proof. The surface also has melamine coating.

Description/Composition

The materials referred to are melamine surfaced highpressure laminates (HPL) according to the European norm EN438 and to ISO 4586. They are supplied in sheet form in a variety of sizes and thicknesses and surface finishes. Laminates basically consist of paper and thermosetting synthetic resins, paper comprising more than 60% of the product. The remaining 30-40% consists of cured phenol formaldehyde resin for the core layers and melamine- formaldehyde resin for the surface layers. Both resins belong to the group of thermosetting resins. They are irreversibly interacted to produce a finished product with a high molecular weight. Cross linked chemical bonds are formed during the curing process under conditions of high pressure and temperature resulting in a non-reactive stable material with characteristics which are totally different from those of its component parts. Where fire retardence is required, the laminate core is treated with an additive which does not contain halogens Storage and Distribution: Storage and transportation should be carried out in accordance with the General Processing Recommendations for HPL; no special precautions need to be taken. For transportation, HPL is classified as a non-hazardous product no labelling required.

Handling and Machining of HPL

The usual safety requirements of fabrication and machining should be observed with regard to: Dust Extraction, Dust Collection, and Fire Precautions Because of the possibility of sharp edges, protective gloves should always be worn when handling laminates. The contact with dust from HPL does not present any special problems, however a small percentage of personnel may be sensitive or allergic to machining dust in general.

Environmental and Health Aspects in Use

Laminates are cured and therefore chemically inert. There is no migration affecting foodstuffs and release of gases. HPL are approved for contact with foodstuffs. Due to their low permeability HPL act as a barrier against formaldehyde emissions coming from the wood based substrates. Its own formaldehyde emission level is far below the limit for wood based materials. The surfaces are resistant to all common household solvents and chemicals and have therefore been used for many years in applications where cleanliness and hygiene are important. The non-porous HPL surface is easy to disinfect with hot water, steam and all types of disinfectants used in hospitals and other commercial applications.

HPL in Fire Situations

Laminates are difficult to ignite and have properties that retard “spread of flame” thus prolonging evacuation time. Due to incomplete burning as with any organic material, hazardous substances are to be found in the smoke. However, laminates are capable of meeting the best performance for organic surface materials specified in the French standard NFF 16101 (at least class F2 for smoke density and toxicity). In dealing with fires in which laminates are involved the same firefighting techniques should be employed as with other wood based materials.

Energy Recovery

On account of their high calorific value (18-20 Mj/Kg) laminates are ideal for thermal recycling. When burnt completely at 700° laminates produce water, Carbon Dioxide and oxides of Nitrogen. Therefore HPL comply with the Kreslaufwirtschaftsgesetz. Well contained burning processes are achieved in modern officially approved incinerators. Ashes of this process can be brought to controlled waste disposal sites.

Waste Disposal

HPL can be brought to controlled waste disposal sites according to current national and/or regional regulations. ABET LAMINATI SpA herewith declares that the above mentioned product does not contain the following substances;

PENTACHLOROPHENAL, ASBESTOS, HALOGENS
HEAVY METALS Including the following; (ANTIMONY, BARIUM, CADMIUM, CHROMIUM (III), CHROMIUM (IV), LEAD, MERCURY, SALANIUM)

According to EN 438-1 2005 Annex A; ABET LAMINATI SpA also declares that the above mentioned product does not contain PBB or PBDE according to Directive 2002/95/EC of the 20th November 2003.