Gemini-2

Cable shield cutter / scriber

Gemini-2

Overview

The Gemini-2 is Laser Wire Solutions' dedicated shield scribing and cutting system. With a large 5x7" working area the machine is capable of cutting the shields of multiple cables at once. As with our other systems the unit is simple to use, requires almost no maintenance and is flexible enough for all your laser stripping needs.

  • Industrial, sealed maintenance free laser technology 
  • Dual laser focus nozzles for cutting the shield from above and below sequentially to create a 360 degree cut or scribe of the shield
  • Large 5 x 7 " work area. Strip multiple cables held on a fixture plate for high productivity 
  • Dual axis motion (X & Y) to provide programmable cut position
  • Runs from a standard 115 / 230 V electrical supply with no compressed air requirement

Application Range

Processing Types

The Gemini-2 system is optimized to process tinned micro-coax shields and aluminized mylar foils.

Left: Micro-coax with a tinned shield that has been scribed and snapped with a Gemini-2.

RIght: Aluminized mylar foil that has been cut with the Gemini-2 system

Materials

The Gemini laser system is optimized for cutting metal whilst being reflected or transmitted by most polymers.

  • Scribing tinned braid (create a shallow groove in the tinned braid to allow it to be snapped.
  • Aluminized mylar foil
 

When scribing micro-coax braid (typically cable OD of <0.25 mm (0.01")) the shield is tin dipped in order to create a solid mass of solder and braid. The Gemini-2 is then programmed to cut a shallow groove in the shield. This "scribe" line is similar to the method used to cut glass. Once scribed, the shield snaps cleanly at the scribe line - cutting all braid strands at the same position.  As the laser beam does not penetrate the braid - it does not matter what the underlying dielectric insulation composition is. For foil cutting, the laser cuts right through the thin foil layer. The laser radiation does hit the underlying layers - so there is a small risk of heat damage. If the underlying plastic material is light colored (ideally white or transparent), the laser does not interact strongly and a robust cutting process can be developed for the foil. For dark colors (particularly black) it may be difficult to find settings that cut the foil without damaging the underlying insulation.

Technical Data

Min. Outer Cable Diameter

0.025 mm (0.001")
Max. Outer Cable Diameter 2.5 mm (0.1")
Stripping Length Increments 0.1 mm (0.01")
Strip types Scribed tinned braid, foil cutting
Max. Stripping Length 125 mm (5")
Speed Up to 250 mm/s (10"/s) 
Cable Loading Via fixture plate - up to 10 cables at once
Dimensions (L x W x H) 720 x 620 x 1000 mm (28 x 25 x 40")

More Info

The Laser Wire Solutions Gemini-2 cuts tinned micro-coax shield and aluminized foils. The laser is strongly absorbed by the metallic shield causing it to vaporize. The laser is pulsed with very short duration pulses to ensure no heat is built up in the shield that could damage the underlying insulation. Once cut, the shield can be snapped off revealing the underlying layers. When scribing a foil or tinned shield, the laser light never penetrates to an underlying layer. When cutting foil it is often the case that the light does penetrate - in which case the effect on the underlying plastic layers has to be carefully assessed.

The main applications are for micro-coax shields where the coax outer diameter is less than 0.25 mm (0.01") and for cutting foil shields found in twin-ax type cables.  Using the color touchscreen, the operator selects the desired settings (laser power, laser speed and strip positions)  from the preprogrammed library and all parameters are automatically set.  This unique software system avoids the need to program each laser move individually.

Gemini-2 begins the cutting process when the Operator starts the process via the touchscreen or via the optional footswitch.

The wires/cables are held in position via a configurable fixture plate. Up to ten wires/ cables can be stripped as part of one operation. A standard fixture plate is supplied, but if required a custom plate can be designed for your requirement.