Marking of fabrics and other materials using a laser

• US 6,140,602 A
• Filed: 04/29/1997
• Issued: 10/31/2000
• Est. Priority Date: 04/29/1997
• Status: Expired due to Term

• Current Assignee: RevoLaze LLC (Lear Corporation)
• Original Assignee: TechnoLines LP
• Inventors: Costin, Darryl
• Primary Examiner(s): Evans, Geoffrey S.
• Application Number:
  US08/844,114
• Time in Patent Office: 1,281 Days
• Field of Search: 219/121.6, 219/121.61, 219/121.62, 219/121.68, 219/121.69, 219/121.8, 219/121.83, 219/121.85, 219/121.67, 219/121.75, 8/444
• US Class Current: 219/121.69
• CPC Class Codes: B23K 2103/34 Leather
• CPC Class Codes: B23K 2103/38 Fabrics, fibrous materials
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/067 Dividing the beam into multiple beams, e.g. multifocusing
• CPC Class Codes: B23K 26/0673 into independently operating sub-beams, e.g. beam multiplexing to provide laser beams for several stations
• CPC Class Codes: B23K 26/08 Devices involving relative movement between laser beam and workpiece
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/0846 for moving elongated workpieces longitudinally, e.g. wire or strip material
• CPC Class Codes: D06C 23/00 Making patterns or designs on fabrics
• CPC Class Codes: D06Q 1/00 Decorating textiles
• CPC Class Codes: G06K 1/126 by photographic or thermographic registration recording apparatus for measuring instruments G01D15/00

Abstract

A unique method imparts laser induced patterns and other designs on thin fabrics and leathers. The method uses a laser beam to slightly penetrate the surface of the product at a controlled specific speed. The laser beam is directed at the product either directly or through mirrors, shutters or lenses. The speed of the laser beam relative to the surface of the product is controlled within a predetermined range. Specific identification and control of this relative speed for a particular product are the keys to overcoming technical barriers which have prevented such use of lasers in the past. Preferably a computer is used to provide a signal to a drive mechanism to control the relative speed. The drive mechanism can control movement of the laser, the product, a mirror or a lens.

Claims

1. A method of using a laser for forming a design on a product selected from the group consisting of fabrics and leathers, comprising:

determining, for a specific material of the product, a maximum speed of said specific material relative to the laser, for a given laser power, that will result in a perceivable change for a given laser power, that will result in a perceivable change being formed to said product, and a threshold speed below which at least one of carbonization, undesired burn through or undesired melting of the material of the product will occur; and

contacting a surface of said product with the laser beam to form a design on said surface which changes the surface of the material, and controlling the speed of said laser beam relative to said surface to a range between said maximum speed and said threshold speed.

2. The method described in claim 1 wherein an electronic controller provides a signal to a drive mechanism to control said relative speed.

3. The method described in claim 2 wherein said drive mechanism controls movement of said laser.

4. The method described in claim 2 wherein said drive mechanism controls movement of said product.

5. The method described in claim 4 wherein said drive mechanism controls movement of said product on a roll.

6. A method described in claim 4 further comprising detecting a thickness of said product prior to said contact and providing a signal to said electronic controller to adjust said relative speed.

7. The method described in claim 2 wherein said electronic controller provides signals to a plurality of drive mechanisms to control said relative speed, and wherein said drive mechanisms control movement of a combination of devices selected from the group consisting of said laser, said product, a mirror and a lens.

8. The method described in claim 2 wherein said drive mechanism controls movement of a mirror.

9. The method described in claim 8 wherein said drive mechanism controls movement of a primary mirror and a plurality of secondary mirrors.

10. The method described in claim 2 wherein said drive mechanism controls movement of a lens.

11. The method described in claim 1 wherein said electronic controller is a computer programmed by software to control said relative speed.

12. The method described in claim 1 wherein said laser beam is modulated.

13. The method described in claim 1 wherein a shutter periodically interrupts said laser beam.

14. The method described in claim 1 wherein said fabrics are selected from the group consisting of cotton, rayon, nylon, wool, natural and artificial silk, acetate, flax, polyamide, lavsan, half wool, denim, raincoat fabric, woven and nonwoven canvas, and mixtures thereof.

15. The method described in claim 14 wherein said thin fabric is denim.

16. The method described in claim 1 wherein said leathers are selected from the group consisting of kid leather, lamb leather, pig leather, chamois leather, calf leather, suede and artificial leather.

17. The method described in claim 1 wherein said relative speed is between about 0.01 meters/second and about 1.5 meters/second.

18. The method described in claim 1 wherein said product is selected from the group consisting of rayon silk, nylon silk, raincoat fabric, and shirt and chemise fabric, and wherein said relative speed is between about 0.01 meters/second and about 1.5 meters/second.

19. The method described in claim 18 wherein said relative speed is between about 1.0 meters/second and about 1.4 meters/second.

20. The method described in claim 1 wherein said product is selected from the group consisting of 50% cotton/50% polyamide fabric and denim, and wherein said relative speed is between about 0.01 meters/second and about 1.5 meters/second.

21. The method described in claim 20 wherein said relative speed is between about 0.8 meters/second and about 1.2 meters/second.

22. The method described in claim 1 wherein said product is selected from the group consisting of artificial leather and pig leather, and wherein said relative speed is between about 0.01 meters/second and about 1.5 meters/second.

23. The method described in claim 22 wherein said relative speed is between about 0.03 meters/second and about 0.07 meters/second.

24. The method described in claim 1 wherein said surface is contacted by a laser beam generated by a CO₂ laser at a distance between about 0.08 meters and about 0.5 meters from said surface, wherein said laser has a radiation capacity between about 5 watts and about 150 watts, and wherein said laser beam has a wavelength of about 10.6 micrometers.

25. A method as in claim 1, wherein said contacting operates to form a design on said surface which causes a change in surface height of at least a portion of the surface.

26. A material marking apparatus, comprising:

a marking surface, adapted in operation to hold a material to be marked;

a laser device, producing a laser beam, said laser device being placed with its output facing said marking surface, and said laser beam being directed toward a location on said marking surface;

a drive mechanism, operating to change a position of said laser beam on said marking surface according to an applied command; and

a controller, connected to said drive mechanism and automatically producing said command to control said position of said laser beam on said marking surface, said controller controlling said drive mechanism to automatically control a speed of movement of said laser beam on said marking surface to a critical operating speed, said critical operating speed being dependent on the specific characteristics of the material being used, and being between a) a threshold speed where the laser beam will undesirably damage the material by one of undesirably fully penetrating the material, carbonization of the material, undesired melting or undesired burn-through of the material, and b) a maximum speed above which a desired imprint will not be formed on the material, to thereby change a surface of the material to a desired pattern on said material without undesired damage.

27. An apparatus as in claim 26 wherein said drive mechanism is a driving element coupled to move the laser, and wherein the controller includes a pre-stored program indicative of said desired pattern, said controller providing information to said driving element indicating with specific movement and timing information necessary to form said desired pattern based on said prestored program, said movement occurring at said critical operating speed.

28. An apparatus as in claim 26, further comprising a thickness sensor, operating to automatically sense a thickness of said material upon which said critical operating speed is determined, and providing an output to said controller, said controller including an element for operating to adjust said critical operating speed based on the thickness sensed by said sensor, and to produce said command to control said drive mechanism to move said laser beam on said material to said critical operating speed determined based on said characteristic which was automatically sensed.

29. An apparatus as in claim 26, wherein said critical operating speed is a speed that creates a design on said surface which causes a change in surface height of at least a portion of the surface.

30. An apparatus as in claim 26, further comprising a characteristic sensor, operating to automatically sense a characteristic of said material upon which said critical operating speed is determined, and providing an output to said controller, said controller including an element for operating to adjust said critical operating speed based on the characteristic sensed by said sensor, and to produce said command to control said drive mechanism to move said laser beam on said material to said critical operating speed determined based on said characteristic which was automatically sensed.

31. An apparatus as in claim 26 wherein said controller determines said critical operating speed as a function of all of a) a particular material being used, b) a thickness of the material, c) power and wavelength of the laser, d) distance between the laser and the material, and e) a particular design being formed.

32. An apparatus as in claim 26 wherein said drive mechanism is a driving element coupled to move the laser, and wherein the controller includes a pre-stored program indicative of said desired pattern, said controller providing information to said driving element indicating with specific movement and timing information necessary to form said desired pattern based on said prestored program, said movement occurring at said critical operating speed.

33. An apparatus as in claim 32 wherein said marking surface includes a roll having an outer surface including material thereon, and wherein said drive mechanism is a product drive connected to rotate said roll, said controller connected to said product drive to control a speed of movement of the roll.

34. An apparatus as in claim 33 wherein said drive mechanism further comprises a laser moving element, moving said laser relative to said roll, said controller controlling movement of said roll to control a first dimension of movement of the laser beam, and controlling a second dimension of movement of the laser beam by moving said laser.

35. An apparatus as in claim 33, further comprising a mirror, and said drive mechanism is also attached to said mirror, said mirror placed in a path of said laser beam to deflect said laser beam towards said marking surface, movement of said laser beam in a first dimension being controlled by movement of said roll and movement of said laser beam in a second direction being controlled by moving said mirror.

36. An apparatus as in claim 35, wherein said characteristic is thickness of the material, and said sensor is a thickness sensor.

37. An apparatus as in claim 35 wherein said mirror is a primary mirror and further comprising at least one secondary mirror, and at least one drive mechanism associated with said secondary mirror, said primary mirror controlling movement of said laser in a first direction and said secondary mirror controlling movement of the laser in the direction of a different position of the material, thereby spreading the laser relative to the material.

38. An apparatus as in claim 26 wherein said drive mechanism is a product drive coupled to move said marking surface, and wherein the controller includes a pre-stored program indicative of said desired pattern, said controller providing information to said driving element indicating with specific movement and timing information necessary to form said desired pattern based on said prestored program.

39. An apparatus as in claim 26 further comprising a mirror, positioned to receive said laser beam and to deflect said laser beam,

wherein said drive mechanism comprises a mirror drive, connected to said mirror and moving said mirror to move in vertical and horizontal directions based on commands from said controller,

wherein said controller controls said mirror drive to move in said directions to move the laser beam on the marking surface at said critical operating speed to locations based on said stored program.

40. An apparatus as in claim 39 further comprising a second mirror operating to spread the laser beam over the marking surface.

41. An apparatus as in claim 26 further comprising a shutter, positioned in a path of the laser beam, and operating to periodically interrupt the laser beam from reaching said marking surface, said shutter including a first shutter portion which does not interrupt the laser beam, a second shutter portion which does interrupt the laser beam, and a movement mechanism which moves said shutter between positions where said first shutter portion and said second shutter portion are in the beam of light, periodically interrupt passage of the laser beam.

42. An apparatus as in claim 41 wherein said controller includes a program which indicates areas on the marking surface where portions of the patterns are not desired to be formed, and which commands said shutter to use said second portion to block said laser beam at said locations where said pattern portions are not being formed and commands said shutter to use said first portion to pass said laser beam at locations where said design is being formed.

43. An apparatus as in claim 26 further comprising a lens, coupled to receive an output of said laser beam, and coupling said laser beam toward said marking surface.

44. An apparatus as in claim 43 further comprising a drive mechanism, coupled to said lens, and operating to move said lens.

45. An apparatus as in claim 44 wherein said drive mechanism operates to rotate said lens, and laterally move said lens.

46. A material marking apparatus, comprising:

a marking surface, adapted in operation to hold a material to be marked;

a laser device, having an output beam which is directed toward a spot on said marking surface;

a drive mechanism, changing a relative position between said laser beam and said marking surface, according to an applied command;

a controller connected to said drive mechanism to command movement of said drive mechanism to a relative position between said marking surface and said laser beam, said controller controlling a speed between said marking surface and said laser beam to a critical operating speed within a predetermined range between a) a threshold speed where the laser beam results in undesired damage to the material and b) a maximum speed where the laser beam does not produce altering to a surface of the material, to thereby form a change to said material without undesirably damaging said material;

a material sensing element, operating to automatically sense a characteristic of said material which affects a propensity of said material to be altered by said laser beam; and

said controller also being responsive to said characteristic that is sensed by said material sensing element, and said controller altering said critical operating speed based on changes in said material characteristic, to control said laser to alter the surface of the material.

47. An apparatus as in claim 46, wherein said critical operating speed is a speed that creates a design on said surface which causes a change in surface height of at least a portion of the surface, and wherein said change to said material is a change to said surface height.

48. An apparatus as in claim 46 wherein said material sensing element is a thickness sensor and said characteristic is thickness.

49. An apparatus as in claim 48 wherein said computer controls said drive mechanism to maintain a speed automatically controlling said position of said laser beam on said marking surface, said controller controlling a speed of movement of said laser beam on said marking surface within a predetermined range, said speed of movement controlled to a critical operating speed, said critical operating speed being between a threshold speed where the laser beam damages the material by one of fully penetrating the material, carbonization of the material, melting or burn-through of the material, and a maximum speed beyond which a desired imprint will not be formed on the material, to thereby print a desired pattern on said material.

50. A method of forming a pattern on a material, comprising:

providing a laser beam which shines on a material to be processed;

moving a position of said laser beam relative to said material;

sensing a characteristic of said material; and

using a computer to adjust a speed of said laser beam relative to said material, said computer maintaining said speed at a critical operating speed that is between a maximum speed beyond which a desired pattern will not be formed on said material, and a minimum operating speed below which undesired damage to the material will result, and said computer responsive to said characteristic sensed by said sensing to determine said critical operating speed at which the laser beam is driven relative to the material, whereby an operation on a first material with a first characteristic is operated at a different relative speed than an operation on a second material with a second characteristic different than said first characteristic.

51. A method as in claim 50 wherein said characteristic being sensed is thickness, wherein said characteristic is automatically sensed, and wherein said different operating speed is used for a material having a first thickness compared with a material having said second thickness.

52. A method as in claim 50, wherein said critical operating speed is a speed that creates a design on said surface which causes a change in surface height of at least a portion of the surface, and further comprising changing a surface height of said material by scanning said laser at said critical operating speed.

53. A method of forming a discontinuous design on a material, comprising:

providing a material and a laser beam;

selectively allowing said laser beam to pass to said material, based on an applied command;

selectively moving said laser beam relative to the material based on an applied command; and

storing a pattern forming program in an automatic controller, said pattern forming program including information indicative of a discontinuous pattern to be formed on the material, said discontinuous pattern including at least two unconnected parts, and producing said commands for said allowing said laser beam to pass to said material, and to selectively move said laser beam relative to said material, said commands including a first command which commands said laser beam to pass to said material during times when it is desired to form said design on said material, and a second command which commands no laser beam during times when it is desired to form the discontinuity in the pattern, to thereby form a pattern which has discontinuous portions further comprising using said controller to determine a desired speed of relative motion between said laser beam and said material based on characteristics of the material being used, said speed being a critical operating speed which is between a) a threshold speed where the laser beam will damage the material by one of undesirably fully penetrating the material, carbonization of the material, melting or burn-through of the material, and b) a maximum speed above which a desired imprint will not be formed on the material.

54. A method as in claim 53 further comprising using said controller to determine a desired speed of relative motion between said laser beam and said material based on characteristics of the material being used, said speed being a critical operating speed which is between a) a threshold speed where the laser beam will damage the material by one of undesirably fully penetrating the material, carbonization of the material, melting or burn-through of the material, and b) a maximum speed above which a desired imprint will not be formed on the material.

55. A method as in claim 54 wherein said movement is effected by moving an output of the laser beam.

56. A method as in claim 53, further comprising changing a surface height of said material by moving said laser beam on said surface.

57. A discontinuous material scribing apparatus, comprising:

a marking surface;

a laser producing a laser beam;

a drive mechanism;

a laser selecting device, located between said laser beam and said marking surface, and having at least two positions, a first position in which said laser beam is unobstructed and impinges on said marking surface and a second position in which said laser beam is prevented by said laser selecting device from reaching said surface; and

a controller, controlling at least said drive mechanism and said laser selecting device, said controller storing a stored program indicating a desired pattern to be formed on said marking surface, said desired pattern including at least a first design portion which extends from a first part to a second part, a second design portion which does not connect with said first design portion, said second design portion extending from a third part, unconnected to said second part, and said second design portion extending to a fourth part, said controller controlling said drive mechanism and said laser selecting device, to;

move said drive mechanism to said first part and move said laser selecting device to said first position so said laser beam shines on said material;

then move said laser beam to said second part;

then move said laser selecting device to said second position so that said laser beam is prevented from reaching said material;

then move said drive mechanism to said third part;

then move said laser selecting device to said first position so that said laser beam shines on said material; and

then move said drive mechanism to said fourth part to end a discontinuous part of the pattern wherein said controller also controls a speed of said drive mechanism and said critical operating speed being dependent on characteristics of the specific material being used and characteristics of a design being formed.

58. An apparatus as in claim 57, wherein said controller determines said critical operating speed as a function of all of a) a material material being used, b) a thickness of the material, c) power and wavelength of the laser, d) distance between the laser and the material, and e) a particular design being formed.

59. A device for forming a pattern on a material, comprising:

a marking surface, adapted in operation to hold a material to be marked;

a laser device, producing a laser beam, said laser device being placed with its output facing said marking surface, and said laser beam being directed toward a location on said marking surface;

a drive mechanism, operating to change a position of said laser beam on said marking surface according to an applied command;

an optical beam width adjusting element, coupled between an output of said laser beam and said marking surface, and operating to adjust an effective width of marking of the laser beam, to effectively adjust an effective width of a pattern portion that is formed by the laser beam on said marking surface; and

a controller, operating according to a stored sequence which includes information indicating a desired pattern to be formed on said marking surface, said controller producing an output which controls said optical beam width adjusting device to adjust the width of said pattern portion according to a width stored in said stored sequence, said stored sequence including a first design portion which has a thinner width, said controller operating to control said optical beam width adjusting device to command the formation of a thinner width pattern portion responsive to said first design portion, and said stored sequence including a second design portion which commands the formation of a thicker width pattern portion, said controller operating to control said optical beam adjusting device to command said thicker width pattern portion responsive to said second design portion.

60. A device as in claim 59, wherein said controller controls said laser to change a surface height of said material by moving said laser beam on said surface.

61. A device as in claim 59 wherein said controller also controls a relative speed between said marking surface and said laser beam, said relative speed being a critical operating speed which is between a) a threshold speed where the laser beam will damage the material by one of undesirably fully penetrating the material, carbonization of the material, melting or burn-through of the material, and b) a maximum speed above which a desired change will not be formed on the material, and said critical operating speed being dependent on characteristics of the material being used.

62. A device as in claim 61 wherein said optical beam width adjusting element includes a lens.

63. A device as in claim 62 wherein said lens includes a moveable portion, moving to change a position of said lens, and a controllable drive mechanism, controlling movement of said lens, said controller commanding said moveable drive mechanism to move in a way which varies a width of the optical beam responsive to said stored sequence.

64. A device as in claim 61 wherein said optical beam width adjusting element includes a moveable mirror.

65. A device as in claim 64 wherein said moveable mirror includes a moving element, connected to said moveable mirror and controlling said moveable mirror in a way to increase an optical beam width of its output.

66. A device as in claim 65, wherein said beam width is increased by scanning the mirror alternately in directions perpendicular to a desired width.

67. A device as in claim 65 further comprising a plurality of additional mirrors, optically coupled to said laser beam, and moving to adjust a position of said laser beam.

68. A method of forming a design on a material, comprising:

providing a laser device and a material holding surface relative to one another;

selectively operating the laser device, such that an output of the laser device impinges on the material holding surface;

moving a position of said output of said laser device on said material holding surface;

storing a program indicating a desired pattern to be printed on a material which will be placed on the material holding surface, said program indicating said desired design including at least a first stored part indicating a thicker portion area of the design, and a second stored part indicating a thinner portion area of the design; and

controlling a movement between said laser beam and said material holding surface according to the stored program, including controlling an output of said laser beam to form a thicker portion of the design at the first portion and to form a thinner portion of the design at the second portion.

69. A method as in claim 68 further comprising controlling a speed of said laser beam on said material to a critical operating speed which is between a) a threshold speed where the laser beam will damage the material by one of undesirably fully penetrating the material, carbonization of the material, melting or burn-through of the material, and b) a maximum speed above which a desired change not be formed on the material, and said critical operating speed being dependent on characteristics of the material being used.

70. A method as in claim 69 wherein said controlling an output width of said laser beam comprises providing a mirror, and commanding said mirror to scan its movement in a way which spreads the beam on the material.

71. A method as in claim 69 wherein said controlling an output width of said laser beam comprises moving a moveable lens in a way which adjusts an effective beam width on the material.

72. A method as in claim 71 wherein said material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

73. A method of forming a pattern on a material, comprising:

obtaining a specific material to be processed;

obtaining a laser to be used to mark said material;

determining, for said specific material, a threshold speed of scanning for said laser, below which undesired damage to the material will be caused;

determining, for said specific material, a maximum speed above which a desired physical change to the material will not be formed; and

commanding the laser to operate on the material to physically change the material in the form of a pattern on the material, by moving a position of the laser beam on the material at a process operating speed between said threshold speed and said maximum speed which are determined for the specific material.

74. A method as in claim 73 wherein said undesired damage to the material includes at least one of carbonization, melt through or undesired burn through.

75. A method as in claim 73 wherein said process operating speed is determined by considering all of at least a particular material, a thickness of the material, characteristics of the laser beam and a particular design to be formed.

76. A method as in claim 75 wherein said forming comprises unrolling material from a roll having an outer surface including material thereon by rotating said roll, said process operating speed being, at least partly, a speed of movement of said roll.

77. A method as in claim 76 further comprising also moving said laser relative to said roll, and controlling movement of said roll to control a first dimension of movement of the laser beam, and controlling a second dimension of movement of the laser beam by moving said laser.

78. A method as in claim 76, further comprising using a mirror to deflect said laser beam towards said material, and controlling movement of said laser beam in a first dimension by movement of said roll and movement of said laser beam in a second direction by movement of said mirror.

79. A method as in claim 78 further comprising at least one secondary mirror to control movement of said laser in a direction different from a direction of control by a primary mirror, thereby forming a thicker part of a pattern by effectively spreading the laser relative to the material.

80. A method as in claim 78 further comprising using another mirror to move the laser beam in a way that effectively spreads the laser beam over the marking surface.

81. A method as in claim 73 further comprising automatically determining a thickness of said material;

and

wherein said process operating speed is determined at least partly as a function of said sensed thickness.

82. A method as in claim 73 wherein said maximum and minimum speed determining comprises determines said process operating speed as a function of all of a) a particular material being used, b) a thickness of the material, c) power and wavelength of the laser, d)distance between the laser and the material, and e) a particular design being formed.

83. A method as in claim 73 wherein said moving comprises moving the laser, and further comprising storing a prestored program indicative of said desired pattern, and providing information to indicate specific movement and timing information necessary to form said desired pattern based on said prestored program, said movement occurring at said process operating speed.

84. A method as in claim 73 wherein said moving comprises moving said material, and further comprising storing a pre-stored program indicative of said desired pattern, and providing information to indicate specific movement and timing information necessary to form said desired pattern based on said prestored program, said movement occurring at said process operating speed.

85. A method as in claim 73 further comprising using a mirror to deflect said laser beam to a desired position by commanding said mirror to move in vertical and horizontal directions at said process operating speed to locations based on said stored program.

86. A method as in claim 73, further comprising a automatically sensing a characteristic of said material upon which said critical operating speed is determined, and using said automatically sensed characteristic to adjust said process operating speed,

to produce said command to control said drive mechanism to move said laser beam on said material to said critical operating speed determined based on said characteristic which was automatically sensed.

87. A method as in claim 86, wherein said characteristic is thickness of the material.

88. A method as in claim 73 further comprising periodically interrupting the laser beam prior to its reaching said material.

89. A method as in claim 88 further comprising storing a program which indicates areas on the marking surface where portions of the patterns are not desired to be formed, and which commands blocking said laser beam at said locations where said pattern portions are not being formed and commands passing said laser beam at locations where said design is being formed.

90. A method as in claim 73 further comprising using a lens to receive an output of said laser beam, and couple said laser beam toward said marking surface.

91. A method as in claim 90 further comprising moving said lens to change a position of the laser beam.

92. A method as in claim 91 further comprising rotating said lens, and laterally moving said lens.

93. A method as in claim 73, wherein said forming comprises controlling said laser to change a surface height of said material by moving said laser beam on said surface.

94. A method of forming a pattern on a fabric material, comprising:

experimenting on a plurality of different kinds of fabric materials to determine a critical operating speed for each material, said critical operating speed being one where a laser beam forms a desired pattern on said material without damaging the material in an undesired way, said critical operating speed being between a maximum speed at which a desired change to the material is not formed in the material, and a minimum speed below which undesired damage is caused to the material;

determining a specific material to be used;

determining a critical operating speed from the previously-obtained critical operating speeds determined by said experimenting; and

forming a pattern on the material by illuminating the laser beam on the material and moving the laser beam on the material at the selected critical operating speed.

95. A method as in claim 94 further comprising using an automatic characteristic sensor to automatically determine a characteristic of said material;

and

automatically determining said process operating speed based on at least an output of said automatic characteristic sensor.

96. A method as in claim 95 wherein said automatic characteristic sensor is a thickness sensor and said process operating speed is determined at least partly as a function of the automatically sensed thickness.

97. A method as in claim 94 wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

98. A laser apparatus as in claim 94, wherein said change is one of a physical change or a chemical change or both a chemical change and a physical change.

99. A method of altering characteristics of a material, comprising:

determining at least one characteristic of the material, said at least one characteristic being of a kind which affects a propensity of the material to be physically altered by a radiation source;

using said at least one characteristic to determine a radiation source power and speed of movement of an output of the radiation source over the material that will cause a desired structural change of the material without undesired damage to the material;

storing information in a controller indicating a desired pattern to be formed on said material; and

using said controller to control said radiation source according to said determined radiation source power and speed of movement determined in said using and according to said stored information indicating the desired pattern.

100. A method as in claim 99 further comprising an initial step of modeling a plurality of said materials using said characteristics to determine said power and speed from the modeled characteristics.

101. A method as in claim 99 wherein a part of said stored information indicating the desired pattern includes an indication of a width of a portion of the desired pattern to be formed on said material, and further comprising altering said width according to said stored information.

102. A method as in claim 99 wherein said determining characteristics of the material comprises automatically determining said characteristics.

103. A method as in claim 102 wherein said characteristic includes thickness of the material, and the automatic detecting is carried out by a thickness detector.

104. An apparatus for forming a pattern on a material, comprising:

a laser, producing a laser beam output;

an element holding device, which in operation, holds a material on which a pattern is to be formed;

a laser beam moving element, effecting a movement of said laser beam on said material when said material is located on said element holding device; and

an automated controller, which stores a pre-stored series of information indicative of pattern positions will form the pattern on said material, and also obtaining information about said material, and determining a critical parameter of said laser beam relative to said material, said critical parameter being a parameter allowing said pattern to be formed by physical altering of a surface of said material without undesired damage to the material, said automated controller controlling said laser and moving speed according to said information indicative of said critical parameter, and also controlling the position of the laser beam according to the prestored series of information to form a pattern on the surface without undesired damage to the surface.

105. An apparatus as in claim 104 wherein said critical parameter is a critical operating speed of the laser beam relative to said holding device.

106. An apparatus as in claim 104 wherein said moving device includes at least one movable mirror in the path of laser beam output, deflecting the laser beam to the material.

107. An apparatus as in claim 104 wherein said material is a fabric material.

108. An apparatus as in claim 107 wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

109. An apparatus as in claim 104 wherein the material is an undyed material.

110. An apparatus as in claim 104 wherein said laser beam moving element is a moving device on the element holding device.

111. An apparatus as in claim 104 wherein said laser beam moving element is a moving element on the laser.

112. A method of producing a design on a material, comprising:

producing a focused beam of radiation, said focused beam being directed to a location where a material to be altered is adapted to be located;

storing pre-stored data which represents pattern portions to be formed to represent a pattern to be inscribed on said material;

determining a critical parameter for said beam of radiation on said material based on characteristics of the material being used, and based on a determined maximum speed for the material being used at which less-than-desired change will be caused to said material, resulting in an imperfect pattern being formed on said material, and a determined minimum operating speed for the material being used at which undesired damage to the material will be formed; and

commanding said beam of radiation to move at the critical parameter to locations indicated by said stored pattern portion.

113. A method as in claim 112 wherein said beam of radiation is a laser beam and said critical parameter is a critical operating speed of the laser beam relative to the material.

114. A method as in claim 112 wherein said information includes at least first and second discontinuous pattern segments which include said desired pattern including at least a first design portion which extends from a first part to a second part, a second design portion which does not connect with said first design portion, said second design portion extending from a third part, unconnected to said second part, and said second design portion extending to a fourth part,

wherein said commanding said beam of radiation comprises:

moving said beam of radiation to said first part so said laser beam shines on said material to begin said first discontinuous pattern segment;

then moving said beam of radiation to said second part at said critical operating speed for said material;

then interrupting said beam of radiation so that said beam of radiation is prevented from reaching said material to thereby end said first discontinuous pattern segment;

then commanding movement of said beam of radiation to said third part;

then starting said beam of radiation when it is located at said third part to begin said second discontinuous pattern segment;

then moving said beam of radiation to said fourth part at said critical operating speed to end the second discontinuous pattern segment.

115. A method as in claim 114 wherein said beam of radiation is a laser beam.

116. A method as in claim 112 wherein said beam of radiation is a laser beam.

117. An apparatus for scribing a pattern onto a material using a laser, comprising:

a numerically controlled laser system including a working surface on which a material to be processed is adapted to placed, a laser portion which produces a laser output and directs said laser output toward said working surface, and a numerical control portion which stores control information commanding motion between said laser output and said working surface, said numerical control portion storing information indicating;

(1) for a specific kind of material being used, information indicating a critical operating speed at a specified laser power, said critical operating speed being between a maximum speed that is too fast to cause a desired change to a surface of the material and a minimum speed, below which undesired damage to the material can occur, and (2) information indicative of a plurality of desired pattern segments which together form the desired pattern to be formed, said numerically controlled laser system responsive to said desired pattern segments to move the laser beam over the material in areas corresponding to said desired pattern segments and to thereby form the pattern on the material.

118. An apparatus as in claim 117 further comprising a laser blocking element with a first position in which the laser beam is allowed to pass, and a second position in which the laser beam is not allowed to pass, and wherein said numerically controlled laser system includes at least information indicative of one discontinuous area where a line segment ends at one location and begins at a second location spaced from said one location and which commands said laser blocking element to allow said laser beam to pass at said one location, commands said laser blocking element to not allow said laser beam to pass at said area between said one location and said second location and commands said laser blocking element to allow said laser beam to pass at said second location.

119. A laser apparatus as in claim 117, wherein said change is a physical change.

120. A method of selectively altering portions of a material to form a desired pattern on the material, comprising:

determining a pattern to be formed on the material;

determining specific characteristics of the material on which the pattern is to be formed;

determining special operational parameters for the material with its specific characteristics, said special operational parameters which allow a focused beam of radiation to form a pattern in the material which changes the material without undesirably damaging the material; and

forming a pattern on said material using the special operational parameters.

121. A method as in claim 120, wherein said focused beam of radiation is a laser beam.

122. A method as in claim 120, wherein said determining comprises determining a critical operating speed for said beam of radiation on said specific material based on characteristics of the specific material being used, and based on a determined maximum speed for the material beyond which a desired physical change to a surface of the material will not be formed, and a determined minimum operating speed for the material being used at which damage to the material will be formed.

123. A method as in claim 120, wherein said material is a fabric material.

124. A method as in claim 123, wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

125. A method of producing a discontinuous design on a material, comprising:

storing information which represents pattern portions to be formed to represent a pattern to be inscribed on said material, said information includes at least first and second discontinuous pattern segments which include said desired pattern including at least a first design portion which extends from a first part to a second part, a second design portion which does not connect with said first design portion, said second design portion extending from a third part, unconnected to said second part, and said second design portion extending to a fourth part;

producing a focused beam of radiation;

determining a critical parameter for said beam of radiation on said material based on characteristics of the material being used, by determining a parameter range between a) a first parameter where a desired change to a surface of the material will not be formed, and b) a second parameter where which an imperfect pattern will be formed on said material, and a determined minimum operating speed for the material being used at which damage to the material will be formed;

moving said beam of radiation to said first part so said beam of radiation shines on said material to begin said first discontinuous pattern segment;

then moving said beam of radiation to said second part using said critical parameter for said material;

then interrupting said beam of radiation so that said beam of radiation is prevented from reaching said material to thereby end said first discontinuous pattern segment;

then commanding movement of said beam of radiation to said third part;

then starting said beam of radiation when it is located at said third part to begin said second discontinuous pattern segment;

then moving said beam of radiation to said fourth part using said critical parameter to end the second discontinuous pattern segment.

126. A method of selectively altering portions of a material to form a desired pattern on the material, comprising:

determining a pattern to be formed on a surface of the material;

determining specific characteristics of the material on which the pattern is to be formed;

determining special operational parameters for the material with its specific characteristics, said special operational parameters which allow a focused beam of radiation to form a pattern in the surface of the material, of a type which causes a change in a height of at least a portion of said surface; and

forming a pattern on said surface of said material which changes the height of the surface of the material, using said special operational parameters determined by said determining special operational parameters.

127. A method as in claim 126, wherein said special operational parameters are a critical operating speed, said critical operating speed being between a) a threshold speed where the laser beam will damage the material by one of undesirably fully penetrating the material, carbonization of the material, melting or burn-through of the material, and b) a maximum speed above which a desired imprint will not be formed on the material, to thereby print a desired pattern on said material.

128. An pattern forming apparatus operating to form a pattern on a flexible material, comprising:

a marking surface, adapted in operation to hold a specific material to be marked;

a laser device, producing a laser beam, said laser device being placed with its output facing said marking surface, and said laser beam being directed toward a location on said marking surface;

a drive mechanism, operating to change a position of said laser beam on said marking surface according to an applied command; and

a controller, determining, for said specific material, a threshold parameter for said laser within which undesired damage to the material will not be caused and within which a desired physical or chemical change to a surface of the material will be caused, said controller controlling said laser device to form a pattern on the material by moving a position of the laser beam on the material using said parameter determined for the specific material.

129. An apparatus as in claim 128, further comprising a characteristic sensor, operating to automatically sense a characteristic of said material upon which said critical parameter is determined, and providing an output to said controller, said controller including an element for operating to adjust said critical parameter based on the characteristic sensed by said sensor, and to produce a command to control according to said parameter.

130. An apparatus as in claim 129, wherein said characteristic is thickness of the material, and said sensor is a thickness sensor.

131. A pattern forming apparatus as in claim 128, wherein said parameter is one which controls said laser to change a surface height of said material by moving said laser beam on said surface.

132. A pattern forming apparatus as in claim 128, wherein said material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture of these materials.

133. An apparatus as in claim 128 wherein said critical parameter is critical operating speed range of said laser relative to said material, beyond which a desired physical change to a surface of the material will not be formed and below which undesired damage to a surface of the material will be caused.

134. An apparatus as in claim 128, wherein said material is a fabric material.

135. A pattern forming apparatus operating to form a pattern on a material, comprising:

a marking surface, adapted in operation to hold a specific material to be marked;

a laser device, producing a laser beam, said laser device being placed with its output facing said marking surface, and said laser beam being directed toward a location on said marking surface;

a drive mechanism, operating to change a position of said laser beam on said marking surface according to an applied command; and

a controller, determining, for said specific material, a threshold parameter for said laser within which less damage will occur to the material than would occur from chemical dyeing process, and within which a desired change to a surface of the material will be caused, and, said controller controlling said laser device to form a pattern on the material by moving a position of the laser beam on the material using said parameter determined for the specific material.

136. An apparatus as in claim 135 wherein said threshold parameter is critical operating speed range of said laser relative to said material, beyond which a desired physical change to a surface of the material will not be formed and below which more damage to the material will be caused than would be caused by chemical dyeing processes.

137. An apparatus as in claim 135, wherein said material is a fabric material.

138. An apparatus as in claim 137, wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

139. An apparatus as in claim 137, wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

140. An apparatus as in claim 135, wherein said threshold parameter is a parameter that creates a design on said surface which causes a change in surface height of at least a portion of the surface, and wherein said change to said material is a change to said surface height.

141. A method of selectively altering portions of a material to form a desired pattern on the material, comprising:

determining a pattern to be formed on the material;

determining specific characteristics of the material on which the pattern is to be formed;

determining special operational parameters for the material with its specific characteristics, said special operational parameters which allow a focused beam of radiation to cause a chemical change in a surface of the material that causes a pattern which can be seen to be formed in the material without undesirably damaging the material; and

forming a pattern on said material using the special operational parameters.

142. A method as in claim 141, wherein said material is a fabric material.

143. A method as in claim 142, wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

144. A method as in claim 141, wherein said threshold parameter is a parameter that creates a design on said surface which causes a change in surface height of at least a portion of the surface, and wherein said change to said material is a change to said surface height.

145. A method as in claim 141, wherein said threshold parameter is critical operating speed range of said laser relative to said material, beyond which the desired chemical change to a surface of the material will not be formed and below which undesired damage to the material will be caused.

146. An apparatus for forming a pattern on a material, comprising:

a CO₂ laser, producing a laser beam output;

an element holding device, which in operation, holds a material on which a pattern is to be formed;

a laser beam moving element, effecting a movement of said laser beam on said material when said material is located on said element holding device; and

an automated controller, which stores a pre-stored series of information indicative of pattern positions will form the pattern on said material, and also obtaining information about said material, and determining a critical parameter of said laser beam relative to said material, said critical parameter being a parameter allowing said pattern to be formed by altering of a surface of said material without undesired damage to the material, said automated controller controlling said laser and moving speed according to said information indicative of said critical parameter, and also controlling the position of the laser beam according to the prestored series of information stored program to form a pattern on the surface without undesired damage to the surface.

147. An apparatus as in claim 146 wherein said critical parameter is critical operating speed range of said CO₂ laser relative to said material, beyond which a desired physical change to a surface of the material will not be formed and below which undesired damage to a surface of the material will be caused.

148. An apparatus as in claim 147, wherein said material is a fabric material.

149. An apparatus as in claim 148, wherein said fabric material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

150. An apparatus as in claim 146, wherein said critical parameter is a parameter that creates a design on said surface which causes a change in surface height of at least a portion of the surface, and wherein said change to said material is a change to said surface height.

151. A method of forming a desired pattern on an undyed fabric type material, comprising:

determining a pattern to be formed on the material;

determining specific characteristics of the material on which the pattern is to be formed;

determining special operational parameters for the material with its specific characteristics, said special operational parameters which allow a focused beam of radiation to form a pattern in the material which can be seen, without undesirably damaging the material; and

forming a pattern on said material using the special operational parameters.

152. A method as in claim 151, wherein said material is one of denim, leather, cotton, rayon, nylon, wool, silk, or a mixture thereof.

153. A method as in claim 151, wherein said pattern is formed by changing a physical structure of the material using said focused beam of radiation.

154. A method as in claim 153, wherein said focused beam of radiation is a laser beam.