Industrial Traceability: Using BarTender Variable Data with Fusion Galvo
Automating Industrial Traceability with Laser Marking
Streamline your industrial marking workflow by integrating BarTender variable data with your Epilog Fusion Galvo G100. This guide walks you through the process of importing data to automate the engraving of serial numbers and barcodes on metal tags.
What is Variable Data Engraving?
Variable data engraving allows you to print a series of unique identifiers, such as serial numbers, QR codes, or barcodes, automatically from a database. Instead of manually updating each design, the software pulls information from a database and sends it directly to the laser.
Beyond Excel: Scaling with ERP and Database Integration
While Excel is a simple example, the BarTender-to-Epilog workflow is built to scale with your business. For enterprise-level operations, you can move beyond static spreadsheets and connect directly to your live production data.
Real-Time Connectivity: Link your laser system directly to SQL, Oracle, or SAP databases.
ERP/MRP Integration: Pull serial numbers and job details directly from your Enterprise Resource Planning software, ensuring the laser marks the most current data in your system.
Print Portals: Utilize BarTender’s web-based Print Portal to allow operators to trigger jobs from a tablet or workstation without ever touching the raw design file, maintaining strict version control.
Material-Specific Marking: Annealing vs. Etching
The Fusion Galvo’s fiber laser source is highly versatile, but achieving the perfect mark depends on how the laser interacts with your specific metal.
Laser Annealing: For medical and aerospace applications where the surface integrity cannot be compromised, annealing is the preferred method.
The Process: By slightly defocusing the beam and adjusting the frequency, the laser heats the metal to create an oxidation layer below the surface.
The Result: A permanent, high-contrast black mark that is smooth to the touch, preventing bacteria growth or material fatigue.
Laser Etching & Engraving: When depth and tactile durability are required, etching is the standard.
The Process: The laser removes a thin layer of material to create a physical groove in the metal.
The Result: A highly durable mark that remains legible even if the part is subjected to heavy abrasion, painting, or powder coating.
Step 1: Prepare Your BarTender Design
Set Page Dimensions: In BarTender, create a layout that matches your physical material. (Example: A 5” x 3” serial tag).
Define Variable Fields: Identify which parts of your design will change. Typically, this includes:
The Serial Number text field.
A Scannable Barcode linked to that serial number.
Step 2: Connect Your Database
To pull unique data into your design, you must link your source file. In this example, we use a simple Excel file to show the capabilites.
Ensure you have an Excel file ready with your list of serial numbers.
In BarTender, go to File > Database Connection Setup.
Follow the Database Setup Wizard:
Select Microsoft Excel as the file type.
Browse and select your specific data file.
Finish the wizard to see your Database Fields appear in the software sidebar.
Step 3: Map Data to Your Design
Now, connect the database logic to your visual elements.
Select the Serial Number field on your tag.
Drag the corresponding database field from the sidebar and drop it onto the selected text.
Repeat this process for the Barcode.
Verify: You can now toggle through your records to see the different serial numbers and barcodes automatically update on the screen.
Step 4: Printing to the Epilog Engraver
Go to File > Print.
Ensure the Epilog Engraver is selected as your printer.
Under Record Selection, you can choose to print all records or a specific range (e.g., records 1–5).
Step 5: Finalizing in the Epilog Dashboard
Once the file is printed, it will appear in the Epilog Laser Dashboard.
View Your Jobs: The dashboard will show the table for the Galvo laser with your metal plate positioned in a jig.
Settings Management: If you have used these materials before, the dashboard can automatically assign your previous “Metal Plate” settings to each page.
Confirm Records: You should see individual tabs for each serial tag (e.g., five tabs for five serial tags).
Step 6: Running the Job
Send the files to the laser.
On the laser’s touchscreen, select the first file in the sequence.
The Fusion Galvo door will close automatically and begin the high-speed engraving process.
Efficiency Tip: Once a job finishes, the door opens. The operator can quickly replace the item or the entire jig and immediately start the next file.
Why Use Fusion Galvo for Serial Tags?
The Fusion Galvo G100 is engineered for high-speed metal marking. When paired with BarTender’s automation, it reduces human error and drastically increases throughput for industrial labeling, asset tracking, and manufacturing.
Meeting Industrial Compliance and Marking Standards
In modern manufacturing, laser engraving helps companies meet regulatory requirements. For industries ranging from aerospace to medical device manufacturing, total lifecycle tracking is the gold standard.
Using the BarTender Automation suite with the Fusion Galvo G100 allows your facility to effortlessly meet the world’s most stringent marking standards.
Aerospace & Defense (MIL-STD-130): Generates permanent, machine-readable 2D Data Matrix codes for Unique Identification (UID).
Medical (FDA UDI): Produces high-contrast, sterilization-proof marks essential for medical device tracking.
Automotive (AIAG): Supports standards for parts identification and recall management.
Firearms (ATF): Easily achieves the .003″ depth requirement and 1/16″ text size mandated by ATF.
Global Supply Chain (GS1): Automates the creation of standardized barcodes for international logistics.
The Fusion Galvo’s fiber source creates high-contrast, tamper-proof marks that withstand extreme heat, chemicals, and abrasion, ensuring your parts remain compliant throughout their entire lifecycle.
