Compact Laser Die Cutter and Label Converter 

This project focused on the design and development of a compact laser die cutting machine for a manufacturer of digital label finishing and converting equipment. The aim was to create a space-efficient solution targeted at start-up converters, combining CO₂ laser technology with practical usability and streamlined operation. Drawing on extensive experience in special purpose machinery and laser integration within the print and packaging sector, SPM Mechanical Engineering supported the client from early concept through to production-ready design.

We were contacted by a client who designed and manufactured digital label finishing and converting machinery. They wanted to design and launch a new compact machine that used a 250watt CO2 laser and 3 axis galvanometer system to convert printed label stock into finished labels. The machine was intended to capture the start-up market and would complement the clients existing range of more advanced converting machinery. 

Our experience of the design and installation of CO2 lasers along with our experience of Special Purpose Machinery design for the print and packaging sector made us the ideal partner. 

Since the new machine was intended to target the start-up market where converters would have limited space in their print shop it was imperative that it was as compact as possible whilst still remaining simple and comfortable for the operator to use. The first stage of the process was to work with the client in order to develop a detailed product specification listing all of the options the machine needed to have. From this, we went on to develop 2D layout sketches showing the material paths through the machine and the way in which the different elements of the design would interact with one another. Once happy with the final machine layout we moved onto the embodiment phase of the project which was to develop the final 3D CAD model for the design. 

Full manufacturing information for the project was created including technical drawings, assembly drawings, BOMs and sheet metal flat pattern DXFs. Ongoing manufacturing, assembly and commissioning support was provided until the first build was ready for demonstration at an international product EXPO. 

Upon successful completion of the Compact Laser Die Cutter Machine, SPM Mechanical Engineering were tasked by the same client to design a range of OEM Laser Die Cutting Modules. These modules needed to be self-contained laser die cutters that included a CO2 Laser source, beam delivery system, 3 axis galvanometer, vacuum cutting surface and fume extraction system. These modules were to be sold to third party label converters, along with the die cutting software, for installation within their machinery lines. An example of such can be seen opposite. We would go on to design a single and double laser variant.