Failure Modes in Laser Marking Additives: What Goes Wrong and How to Fix It

Laser marking additives—often searched as laser marking pigments—frequently fail not because of laser settings, but due to fundamental mismatches between material mechanism, substrate, and application requirements. This article summarizes common failure modes observed in industrial laser marking and provides technically sound alternatives.

Failure Mode 1 — Carbon Black Causes Conductivity or Migration Issues

Carbon black is often the first additive considered for laser marking due to its strong laser absorption. In practice, conventionalcarbon-based broadband laser marking additivesfrequently fail because they:

• introduce unintended electrical conductivity

• migrate or bloom over time

• contaminate light-colored or pastel systems

• interfere with optical, electronic, or dielectric performance

This is commonly observed in medical devices, electronic housings, and light-colored plastics.

Carbon black absorbs laser energy excessively and transfers heat uncontrollably through the polymer matrix, leading to bulk heating rather than localized surface modification.

• ATO (Antimony Tin Oxide) — controlled laser absorption without bulk conductivity

• Black TiO₂ — Sb-free inorganic absorber with improved UV and migration stability

Failure Mode 2 — Organic Pigments Burn or Discolor

Organic pigments may initially respond to laser exposure, but often:

• burn or carbonize under high energy

• fade after thermal or UV aging

• shift color unpredictably

• produce unstable or low-contrast marks

This is especially common under high laser power, long marking cycles, or outdoor exposure.

Organic molecules decompose thermally before controlled surface modification can occur, making them unsuitable for stable industrial laser marking.

• Black TiO₂ — inorganic stability with pigment-like optical behavior

•              BHCP (Cu₂(OH)PO₄)              — laser-activated catalytic precursor enabling stable, high-contrast marking without organic degradation

Failure Mode 3 — ATO Produces Only Black or Gray Marks

ATO is highly effective for contrast generation, but it:

• produces only dark gray or black marks

• cannot generate true decorative colors

• limits visual differentiation in branding or coding applications

ATO operates via a purely thermal absorption mechanism and does not introduce chromatic or chemical color responses.

• BHCP (Cu₂(OH)PO₄)    — enables contrast through laser-induced catalytic and structural effects rather than pure thermal darkening

• Composite Function Black — blended systems prioritizing controlled contrast over color purity

Failure Mode 4 — Laser Power Is Insufficient for Marking

In low-power or compact laser systems, markings may appear incomplete, inconsistent, or low in contrast.

This is common in desktop lasers, inline marking units, thick sections, or reinforced plastics.

Some additives require higher energy density to trigger their marking mechanism and remain inactive under limited laser power.

• Composite Function Black — broad absorption across wavelengths and power ranges

• ATO (optimized particle size) — improved activation efficiency under lower energy density

Failure Mode 5 — Sb-Free or Regulatory Restrictions Apply

Certain regions or applications impose restrictions on antimony-containing materials, delaying qualification or approval.

ATO contains antimony, which triggers additional regulatory scrutiny in medical, electronic, or eco-sensitive markets.

• Black TiO₂ — Sb-free, inorganic, UV-stable solution

• Composite Function Black — when formulation flexibility allows

Failure Mode 6 — Poor Interaction with Ceramic or Electronic Phases

In hybrid systems combining polymers with ceramic or electronic fillers:

• laser marks lack definition

• surface modification becomes inconsistent

• dielectric or electronic performance may be affected

Standard polymer-focused laser marking additives do not interact optimally with ceramic or electronic phases.

• Bi₂O₃ (Bismuth Oxide) — modifier improving laser–ceramic interaction

• Combined formulations with ATO or composite absorbers

Summary: Which Additive Solves Which Failure?

Technical FAQ

No. BHCP is not a decorative green pigment. It functions as a laser-activated catalytic precursor that enables contrast formation through structural and chemical changes.

Most laser marking materials do not generate color through pigmentary mechanisms but through laser-induced physical or chemical transformations.

Contrast stability, readability, durability, and process robustness are the primary performance criteria in industrial laser marking.