Continuous laser stripping with on-the-fly 3D morphological adaptation

Abstract

Selective laser ablation in the automotive sector faces control challenges with large-format parts due to deformation and positioning errors. The industry currently relies on costly jigs and idealised CAD models, resulting in inflexible processes. This article presents a continuous (on-the-fly) laser ablation system that eliminates the reliance on precision jigs through in-situ 3D scanning and a morphological adaptation algorithm. To validate its robustness, a stress scenario was designed: the trajectory of a geometrically flat CAD model was adapted to a real curved plastic test specimen, exaggerating the deformations typical of a radiator grille. The system recalculates the trajectory on the fly through real-time synchronised control between the axes and the laser. The results demonstrate that the adaptive control maintains the optimal focal length and a uniform groove width, correcting the shortcomings of traditional machining and enabling integration into existing conveyor lines.