WO2015130912A1

WO2015130912A1 - Cutting machinery

Info

Publication number: WO2015130912A1
Application number: PCT/US2015/017704
Authority: WO
Inventors: Nikolai MIKKELSON; Steen Mikkelsen
Original assignee: Mikkelsen Converting Technologies, Inc.
Priority date: 2014-02-26
Filing date: 2015-02-26
Publication date: 2015-09-03

Abstract

A cutting system includes a cutting table and a cutting surface transfer station. Cutting table includes a first cutting material and a first conveyor system. Cutting table further includes a cutter system including a pair of side rails and a horizontal rail supporting a cutter and vacuum system is provided to draw air through the top surface of the first cutting material into the table to assist in maintaining a sheet positioned relative to a portion of the surface of the first cutting material.

Description

CUTTING MACHINERY

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present Patent Cooperation Treaty application claims priority to U.S. Patent Application No. 61/945,031 field February 26, 2014 entitled Cutting Machinery and U.S. Patent Application No. 62/064,841 filed October 16, 2014 entitled Cutting Machinery, both of which are incorporated herein in their entirety.

BACKGROUND OF THE INVENTION

[0002] The present application relates generally to the field of cutting materials and more particularly to equipment having a cutting surface for cutting materials with a laser.

SUMMARY

[0003] In one embodiment a cutting system includes a cutting table and a laser cutting material formed of a metal material having a plurality of apertures extending therein.

[0004] In one embodiment a laser cutting material includes a metal material operatively adhered to a carrier material, the metal material having a plurality of apertures formed therein and a plurality of disks being located directly below a respective aperture.

[0005] A process for forming a laser cutting material comprising securing an aluminum foil to a carrier material and creating apertures into the aluminum foil.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which: [0007] FIG. 1 is a top isometric view of a cutting system with a surface loader.

[0008] FIG. 2 is a top isometric view of the cutting system of FIG. 1 with the surface loader in a second engaged position.

[0009] FIG. 3 is a top isometric view of the cutting system of FIG 1 with the surface layer loaded onto the table.

[0010] FIG. 4 is a front view of the cutting system of FIG. 3.

[0011] FIG. 5 is a view of a portion of the surface of FIG. 3.

[0012] FIG. 6 is close up view of FIG. 3 generally taken along area 6-6.

[0013] FIG. 7 is a cross-sectional view taken generally along lines 7-7 of FIG. 6.

[0014] FIG. 8 is cross-sectional view taken generally along lines 8-8 of FIG. 6.

[0015] FIG. 9 is cross-sectional view taken generally along lines 9-9 of FIG. 8.

[0016] FIG. 10 is an isometric view of a surface material.

[0017] FIG 11 is an isometric partial view of the surface material of with SCORES extending across the surface material.

[0018] FIG. 12 is a cross sectional view of the surface material taken generally along lines 12-12 of FIG. 10.

[0019] FIG 13A is a surface material loading station in one embodiment.

[0020] FIG. 13B is a surface material loading station in a second embodiment.

[0021] FIG. 14 is a top isometric view of a cutting system with the surface material positioned on the conveyor material with a graphic material positioned on the surface material.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0022] Referring to FIG. 1 a cutting system 110 includes a cutting table 112 and a cutting surface transfer station 114. Cutting table 112 includes a first cutting material 116 and a first conveyor system 118. Cutting table 112 further includes a cutter system 120 including a pair of side rails 122, 124 and a horizontal rail 126 supporting a cutter 128. Cutter 128 includes a cutting head 130 that may include one cutting tools such as a blade, a router, or other similar cutting tools known in the art. Cutting head 130 may also include a sensor 132 such as an optical detector including but not limited to a CCD camera known in the art to assist in locating a sheet 134 to be cut. In one embodiment a vacuum system is provided to draw air through the top surface of the first cutting material 116 into the table to assist in maintaining sheet 134 positioned relative to a portion of the surface of the first cutting material 116.

[0023] First cutting material 116 may be formed from a self-healing material such as felt with or without appropriate backing material. Other self-healing materials known in the art may also be used. First cutting material 116 in one embodiment extends over a top portion of cutting table 112 extending over a front roller, under a portion of the cutting table 112 and over a rear roller. In this manner, cutting surface forms a continuous surface that may be moved about the table in a continuous manner. This continuous feature allows very long rolls of materials 134 to be moved fore and aft relative to cutting table 112 and then moved from a front portion 138 toward a rear portion 140 and then off to a storing location that is off of cutting table 112 in a vector direction from front portion 138 toward rear portion 140. Cutting material 116 is moved along the y axis by a first and second roller positioned proximate the front 138 and rear 140 respectively of cutting table 112.

[0024] Cutting head 128 may also include a laser cutter directing the output of a high-power laser, by computer, at the sheet 134 of material to be cut. Portions of sheet 134 are then either melts, burns, vaporizes away, or is blown away by a jet of gas leaving an edge with a high- quality surface finish. Since a laser operates at an elevated temperature, self-healing cutting surfaces 116 known in the art may also be melted, burned or vaporized away. In one

embodiment a second cutting material 142 having a higher melting and burning temperature point may be used with cutting table 112. The movement of a cutting head relative to a cutting material is well known in the art. Cutting head 130 may be moved in an x-y direction by movement of cutting head along horizontal rail and by moving the horizontal rail along the vertical rails. It is also possible to include other controls to provide an angular tilt from the z axis so the cutting tool cuts sheet 134 at an angle other than perpendicular to the plane defined by the top surface 136 of sheet 134. Cutting head 130 may also move in an up/down direction along the z axis to move a cutter toward and away from first and or second cutting material 116, 142.

[0025] Referring to FIG. 2, second cutting material 142 is loaded onto cutting table 112 from transfer station 114. In one embodiment second cutting material 142 is formed from a plurality of metal slats 144 movable connected to one another with a connector 146. Referring to FIG. 6 connector 146 is a flexible ribbon that is connected to each slat 144 with a rivet 155, through an opening 153, or other connector known in the art to operatively secure each slat 144 together to form the second cutting material 142. In one embodiment metal slats 144 are formed from an aluminum material or aluminum alloy or other material having a melting and burning

temperature above that of the heat transfer from the laser cutter to the surface second cutting material 142. In one embodiment, cutting table 112 includes a second drive system having a drive belt 148 having a plurality of pins 150 extending therefrom. Each pin 150 being removably received in a corresponding aperture 152 of a slat 144. In one embodiment, drive belt 148 includes a plurality of a pair of pins 150 with each pair of pins 150 being received in a corresponding pair of apertures 152. A drive wheel 154 is driven by a motor (not shown) in a clockwise and counterclockwise moving drive belt in fore and aft direction. In one embodiment, a second drive belt is positioned parallel and spaced form first drive belt 148 includes a plurality of pins 150 that engages corresponding apertures 152 positioned on each slat 144 remotely from the apertures 152 that engage with pins 150 operatively connected with first drive belt 148.

[0026] Referring to FIG. 2, transfer load station 114 is positioned relative to cutting table 114 and each slat is secured to the first and second drive belts by positioning the apertures 152 over the corresponding pints 150. Once the first slat 144 or first few slats 144 are secured to the first and second drive belts, the drive belts maybe driven in a direction toward rear 140 thereby transferring all of slats 144 onto cutting table 112. In one embodiment, pins 150 provide a tight fit with apertures 152 thereby allowing slats 144 to remain connected to pins 150 and the drive belts as slats 144 are moved about a rear roller proximate rear portion 140 and under cutting table 112. In this manner once all of slats 144 are transferred to cutting table 112, slats 144 make a continuous cutting surface that extends over an upper surface of cutting table 112 around the rear portion 140 under a lower surface of cutting table 112 and around front portion 138. Once all of the slats 144 have been transferred to cutting table 112, transfer station 114 may be moved away on roller wheels 164. In one embodiment belts 148 may be formed from a material such as para-aramid synthetic fiber sold under the trademark Kevlar. Slats 144 may be removed from cutting table 112 and transferred to transfer station 114 in a reverse manner. Pins 150 are removed from a first slat or leading edge slat and positioned within transfer station 114, drive belts 148 are moved in a direction such that the slats are moved from the belts 148 into transfer station 114.

[0027] Referring to FIG. 5 each slat 144 includes a first longitudinal edge 158 and a second longitudinal edge 160 spaced from and generally parallel to first longitudinal edge 158. In one embodiment not shown longitudinal edges 158, 160 may be beveled such that when slats 144 are in the flat parallel orientation a portion of edge 158 is below the corresponding edge 160 of an adjacent slat. In this manner the laser is fully blocked from a laser beam extending between adjacent slats 144. Of course other edge geometry that provides a continuous slat surface such that a laser targeted perpendicular to an upper surface 162 of slat 144 would not be able to pass through a region between adjacent slats 144.

[0028] In one embodiment first cutting material 116 moves along with second cutting material 142. In another embodiment second cutting material 142 may be moved independently of the first cutting material 116.

[0029] While second cutting surface has been described as aluminum slats, other types of materials are also contemplated including but not limited to a metal mesh, a para-aramid synthetic fiber such as that sold by Kevlar and having a melting and burning temperature above a corresponding temperature of the laser that may be sued for cutting purposes. Additionally it is contemplated that the first cutting surface include a portion that is formed from a high heat resistant material and positioned either to one side (x-axis) of cutting table 114 such that a laser may be sued for cutting on one side while a traditional blade may be sued on a self-healing type of material such as felt may be on a second side (x-axis) of cutting table 114.

[0030] Referring to FIG. 10 in another embodiment a second cutting material 170 includes aluminum foil 174. In one embodiment the aluminum foil 174 is between lmil (.001 in) and lOmil thick (0.010 in) In one embodiment the aluminum foil is 5 mil thick. In other

embodiments the aluminum foil has a thickness less than lmil and in another embodiment the aluminum has a thickness that is greater than 10 mil thick. In one embodiment the aluminum foil 174 is mounted, adhered or laminated to a carrier material 176. In one embodiment the carrier material 176 is one of polyurethane, fiberglass, or other similar materials. The carrier material in one embodiment is between 1 - 3 mm thick. In one embodiment a 1 mil - 10 mil aluminum foil is sufficient to scatter the laser beam and serves as great cutting underlay when cutting fabrics. In one embodiment the aluminum foil may be pure aluminum or an alloy containing other metals.

[0031] In one embodiment the aluminum foil 174 will be perforated with a plurality of apertures 180 to allow air flow to hold the graphic 134 substrate in place relative to the second cutting material 170 as well as to remove fumes that are created from the cutting process. A vacuum supplied to the underside of the first cutting material 116 draws air through the aluminum foil 174. In an embodiment in which aluminum foil 174 is secured to a carrier material 176, the vacuum will draw air through the apertures in aluminum foil 174 through the carrier material 176 and through the first cutting material 116.

[0032] Referring to FIG. 12 each aperture 180 is formed by punching a disk 182 from aluminum foil 174. Disk 182 is pushed a distance from the top surface 184 of aluminum foil 174 toward a bottom surface 186 of carrier material 176. As a result a gap 188 is created between aluminum foil 174 and disk 182. Disk 182 has an upper surface that is not co-planar with the top surface 184 of aluminum foil 174 when the disk 182 is pushed into the carrier material 176. The arrows in FIG. 12 illustrate the direction of air flow. This air flow caused by the vacuum that draws air from the top region above the top surface 184 downwardly toward bottom surface 186. This vacuum allows a graphic sheet 134 to be cut to be held against the top surface 184 of aluminum foil 174. In one embodiment first cutting material 116 may be moved by conveyor system. The second cutting material is then moved along with the first cutting material 116 and in turn graphic material 134 is moved with the first cutting material and second cutting material as well.

[0033] In one embodiment second cutting material has a thickness of 1.8 mm measured along a vector direction from top surface 184 perpendicularly downward to ward bottom surface 186. In one embodiment disk 182 is positioned half way between upper surface 184 and bottom surface 186. In one embodiment the location of disk 182 is more than or less than 50% of the distance between upper surface 184 and bottom surface 186. The location of disk 182 must provide a sufficient annular opening 188 so that the vacuum can adequately retain graphic sheet 134 against the upper surface 184 during the cutting operation and/or during movement of the second cutting surface about the rollers in the y vector direction as illustrated in FIG 14.

[0034] The combined carrier layer 186 and aluminum foil layer 174 is sufficiently flexible, that they can rolled around the rollers at each end of the cutting machine and act as a conveyer system to transport the fabric thru the system. The combined carrier layer 186 and aluminum foil layer 174 is placed on top of the first cutting surface or primary bel belt which is used for knife cutting. When the operator wishes to switch from laser cutting, he/she will simply remove the combined carrier / aluminum foil and now the primary belt is used for blade cutting. While aluminum is identified as the foil material other materials may also be used. Note that the aluminum foil may have other thicknesses than indicated herein. Also the substrate may be other materials such as but not limited to fiberglass.

[0035] Aluminum foil layer 174 is bonded to carrier layer 176 through at least one of pressure and heat. The application of pressure and/or heat creates a bond layer 178 between the carrier layer 176 and aluminum foil layer 174. The carrier layer may be treated with an adhesive intermediate the carrier layer and the aluminum foil layer, or the carrier layer may be formed of a material that bonds to the aluminum foil layer with the application of pressure and/or heat. For example in one embodiment the carrier layer includes a polyurethane material that melts under the application of pressure and/or heat and bonds to the aluminum foil. Such a bonding process results in a bonded material that does not significantly wrinkle as the composite carrier material and bonded aluminum foil is rolled about the system. The term wrinkle as used herein means a permanent crease or other raised or lowered ridge on the surface of the aluminum foil that is caused by movement of the aluminum foil in the cutting system 110 and/or movement to and from the storage module 114.

[0036] In one embodiment apertures 180 are formed by a punch having a cross section between 50mil and 150mil forming aluminum foil disks 182. The punch separates the disk 182 from the aluminum foil 174 and moves the disk toward the bottom surface 186 of the carrier material 176/ Disks 182 are clipped off evenly by the punch tool, then pressed flat halfway into the carrier material 176 belt without too much of the carrier material protruding on the bottom surface 186 of the carrier material. Stated another way, the movement of disk 182 into carrier material 176 may cause the bottom surface 186 under disk 182 to protrude away from the bottom surface 186 of carrier material casing a dimpled effect. In one embodiment the protrusion of material is between 20mil and 30mil. It is noted that the location of disk 182 downwardly into carrier material 176 is greater than the distance of the protrusion as some of the carrier material 176 is compressed.

[0037] To allow sufficient airflow caused by the vacuum the closeness or density pattern of the holes 180 created by disks 182 can be high between 25%- 45% of the surface area of the aluminum foil 174. The open areas 180 defined by holes 180 help to make the final construction of the belt more flexible when passing by conveyer rollers. The cumulative area defined by all holes 180 is referred to as the open area of the aluminum foil 174. In one embodiment the open area defined as a percent of the total area of aluminum foil 175 is between 25% and 45%. Of course it is contemplated that the percent area of openings 180 to the entire surface area of the aluminum foil 174 may be less than 25% or greater than 45%.

[0038] In one embodiment the punch sizes may be 60 mil, 94 mil, and 150 mil to create openings of varying diameter. In one embodiment disks are 182 are circular creating an annular opening 188. However other noncircular disk shapes are contemplated as well. [0039] In one embodiment, aperture 180 extends clear through aluminum foil 174 and carrier material 176 such that disks 182 are completely removed from second cutting material 170. Maintaining disks 182 within carrier material 176 allow for a greater surface area of aluminum when a laser from above is being used to cut a graphic material 134. If disks 182 are removed completely, there is the possibility that a laser may travel through aperture 180 to the first cutting material 116 and would burn as a result. Disks 182 remaining in carrier material 176 allows for greater hole size providing more flexibility in the first cutting material 170 and providing for enhanced air flow for securing graphic sheet 134 to second cutting material 170 by the vacuum during the cutting process. The energy of the laser used to cut graphic sheets is known in the art. The second cutting material 170 has the material characteristic that the laser when impinging on the second cutting material 170 after cutting through the graphic sheet will not melt or burn the second cutting material 170. Stated another way the melting temperature and the burning temperature of the second cutting material 170 including the aluminum foil 172 and disks is such that the surface of the aluminum foil 172 and disks 182 will not burn when the laser is cutting through a graphic sheet as is known in the art. In one embodiment the graphic sheets are the type that are used for in-store displays and/or posters. Graphic sheets may be paper, Styrofoam, cardboard, plastic or other types of display material.

[0040] Referring to FIGS 14 and 15 in one embodiment the belt is formed from a base substrate of fiberglass and includes a first layer of aluminum foil bonded to the substrate of fiberglass. The first layer of aluminum foil is bonded to the fiberglass with an adhesive. In another embodiment a second layer of aluminum foil is bonded to the first layer of aluminum with an adhesive material. In this embodiment the belt is formed of a base substrate formed of fiberglass, a first layer of aluminum bonded to the fiberglass and a second layer of aluminum foil bonded to the first layer of aluminum with an adhesive.

[0041] Referring to FIGS 14 and 15, the belt may include score lines or creases that run perpendicular to the movement of the belt. The scoring of the aluminum layer or layers allows the belt to be rotated about the rollers while minimizing or eliminating creasing of the aluminum foil layer on the belt as the belt is moved over the rollers from a first orientation on top of the table to a second orientation under the table.

[0042] In one embodiment the aluminum foil 174 is another metal material. In one embodiment the foil 174 is embossed with a pattern. The pattern may be the pattern of the carrier material substrate as the aluminum foil is pressed onto the carrier material. Alternatively a pattern may be embossed onto the aluminum foil itself. It is believed that the embossed patter assists in scattering the laser energy.

[0043] The top aluminum foil layer assists in scattering laser energy applied to the belt to minimize or eliminate burn thru or residues left on the fabric being cut by the cutting machine by the laser. The fabric being referred to is the fabric that is on top of the belt and being cut by the laser.

[0044] In one embodiment, the base layer of fiberglass is woven providing flexure stretch and compression properties so it conveys and rolls up onto the storage module 114 when not in use without causing wrinkles or dents in the top aluminum foil.

[0045] Referring to FIG 13A storage module 1 14 is a bin 190 from which second cutting material 170 may be stored in an accordion fashion. Referring to FIG 13B in one embodiment storage module 114 is a roller system in which second cutting material may be stored on a roller. Roller system 192 may include motors to wind and unwind secondary cutting material 170 between storage module 114 and cutting table 112.

[0046] In one embodiment the aluminum layer is applied to the base layer from a roll having sufficient length to provide the entire length of the cutting surface. In another embodiment the aluminum layer is formed from a plurality of sheets that are secured to one another along their adjacent peripheries to form the entire length and width of the cutting surface.

[0047] The carrier material may be formed of a material having a high friction to the first cutting material conveyer belt which makes indexing and conveying more precise and reliable.

[0048] In one embodiment the apertures 180 are between 1mm and 3mm in diameter and are drilled or punched, spaced 25mm apart in both X and Y direction, thru the aluminum layer(s). The open, woven, carrier material allows the vacuum flow thru it. The vacuum serves to hold the graphic sheet 134 to be cut in position while cutting is taking place by a laser.

[0049] Referring to FIG. 11 in one embodiment, creasing or scoring lines are added in the Y (and potentially X) direction to make the belt more bendable and avoid wrinkles, dents, from the conveying process. Scoring of the surface of the belt may be added to make the aluminum surface more uneven, scattering the laser energy further. An uneven, textured surface, can also be achieved during lamination of the aluminum foil to the woven fiberglass which structure will show thru using high lamination pressure.

[0050] When a user switches to blade cutting, the user removes the aluminum/fiberglass belt onto a roll-up device and the primary blade cutting belt is now exposed and ready for use. In one embodiment the laser belt is relatively light weight so one operator can remove it (or put it back on) with relative ease using the roll-up/off rack.

[0051] In one embodiment the base carrier material that the aluminum foil is adhered to is a Habasit Conveyor Product under the number CM100FBS and in one embodiment the base material the base belt material that the aluminum foil is adhered to includes a cotton fabric having a nonwoven structure that may include a polyester scrim on the traction belt side. In one embodiment a 5 mil aluminum foil is adhered to the base material such as the Habasit material having a thickness of 65 mil with a 5 mil double sided adhesive tape. In one embodiment a user applies a 6 ft x 4ft tape such as a tape sold by Tesa to stick the second cutting material to a first cutting material such as a standard gray conveyer belt known in the art that serves as the cutting surface when the second cutting material is not in use. Stated another way the second cutting material may be employed only when a laser is going to be sued to cut a graphic material.

Second cutting material having a metal foil and a carrier material may be referred to as the metal laminated laser belt or aluminum clad belt.

[0052] Second cutting material 170 has two distal ends. The two distal ends are removably connected together to provide a continuous belt about the cutting table 112. The two distal ends may be connected with a loop and fastener connector or other connectors known in the conveyor belt art.

[0053] A cutting machine includes a standard first cutting material or conveyor belt to which the aluminum clad belt is secured to and/or over. Accordingly, depending on the application the aluminum clad laser belt is left on the cutting machine conveyor belt or it is removed and stored on a storage module

[0054] In one embodiment the base material to which the aluminum foil is secured has sufficient porosity to allow a vacuum to extend there through. A plurality of holes are punched through the aluminum foil while secured to the base material. In one embodiment holes are punched in a row every 1 inch. In another embodiment holes are punched in a row every ½ inch.

[0055] In one embodiment the aluminum foil is 4 mil thick, and the carrier material is 125 mil thick. The apertures 180 each have a diameter of between 100 mil and 125 mil. There are enough apertures in the aluminum foil to provide between 25% and 25% open area. In one embodiment the top surface of disk 182 is positioned between intermediate the top surface of the aluminum foil and the bottom surface of the carrier material. In one embodiment disk 182 has a planar shape and in another embodiment disk 182 may have a non-planar shape such as cone or other arcuate shape. The annular opening created by the disk and the opening 180 of the apertures provide sufficient volume to allow the vacuum to hold the graphic sheet to the aluminum foil during the laser cutting operation and/or provide sufficient volume to provide efficient evacuation of vapors created during the laser cutting operation.

[0056] The cutting table may be used for non-laser operations by removing the second cutting material and using the first cutting material as the conveyor and cutting surface for traditional non-laser cutting operations in which a non-metallic material may be used.

[0057] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein.

Claims

What is claimed is:

1. A cutting apparatus comprising:

a cutting table;

a laser cutting material formed of a metal material having a plurality of apertures extending therein.

2. The apparatus of claim 1, further including a first cutting material located beneath the laser cutting material.

3. The apparatus of claim 1, wherein the laser cutting material has a top surface formed of aluminum foil.

4. The apparatus of claim 3, wherein the aluminum foil has a thickness between 1 mil and 10 mil.

5. The apparatus of claim 4, wherein the aluminum foil is secured to a carrier layer formed of a nonmetal material.

6. The apparatus of claim 5, wherein the laser cutting material includes a plurality of apertures extending through the aluminum foil layer.

7. The apparatus of claim 6, wherein the laser cutting material includes a plurality of disks positioned below each aperture a distance into the carrier material and a distance below a bottom surface of aluminum layer.

8. The apparatus of claim 2, wherein the laser cutting material is removably secured to the first cutting material.

9. The apparatus of claim 7 wherein the bottom surface of the carrier material has a protrusion in a vector direction away from the aluminum foil layer proximate each aperture.

10. The apparatus of claim 9, wherein the aluminum foil is between 1 mil and 10 mils thick.

11. The apparatus of claim 10, wherein the apertures have a diameter between 100 mil and 150 mil.

12. The apparatus of claim 11, wherein the disks are located a distance between 30% and 70% between the top surface of the metal layer and the bottom surface of the carrier material.

13. The apparatus of claim 1, further including a vacuum that draws air through the laser cutting material sufficient to retain a graphic material adjacent to the laser cutting material.

14. The apparatus of claim 13, wherein the vacuum causes air to flow from above the laser cutting material through the apertures around the disks, and through the carrier material.

15. The apparatus of claim 14, wherein the apertures include a plurality of apertures that make up over 25 percent of the top surface area of the laser cutting material.

16. The apparatus of claim 15, wherein the disks are secured to the carrier material.

17. The apparatus of claim 16, wherein the distance that the protrusion extends below the bottom surface of the carrier material is less than the

18. The apparatus of claim 1, wherein apertures extend through the laser cutting material.

19. The apparatus of claim 1, further including a laser having sufficient energy to cut a graphic material supported on the laser cutting material without burning and melting the laser cutting material.

20. A process for forming a laser cutting material comprising:

securing an aluminum foil to a carrier material; and

creating apertures into the aluminum foil.

21. The process of claim 20, wherein creating the aperture into the aluminum foil layer includes punching an aluminum disk from the aluminum foil layer and pressing the aluminum disk into the carrier material and providing an air passage between the aperture and the aluminum disk.

22. A laser cutting material comprising; a material having a first layer operatively adhered to a carrier material, the first layer material having a plurality of apertures formed therein and a plurality of disks being located directly below a respective aperture.

23. The material of claim 22, wherein the disks are supported within the carrier material and positioned intermediate an upper surface of the first layer and a bottom layer of the carrier material.

24. The material of claim 23, wherein an air flow path is defined between the first layer and the disks, and wherein the carrier material is a porous material allowing for air to pass there through.

25. The material of claim 24, wherein the first layer and disks are formed of the same material.

26. The material of claim 25, wherein the first layer and disks are formed from a metal foil.

27. The material of claim 26 wherein the metal foil is an aluminum foil.