The FoilStar is a high-performance laser label marking and cutting solution, purpose-built for industrial label production. Unlike traditional printing methods, it allows any 2D contour to be produced with exceptional durability and anti-tamper properties. Resistant to heat, abrasion, chemicals, and environmental exposure, FoilStar labels provide lasting identification and strong protection against warranty fraud or counterfeiting. Designed for both semi-automated and fully automated production, it is ideal for large-scale manufacturing and high-volume runs.
Produces labels of any 2D shape or size, without the limitations of pad printing or thermal transfer methods.
Labels are resistant to temperature, abrasion, chemicals, and environmental wear—ensuring long service life.
Special adhesive films provide anti-tamper security with built-in break points that prevent complete removal.
Integrated cutting blade severs finished labels directly from the roll for immediate use.
Operates in continuous mode (web of material) or label mode (precut rolls).
External winding device supports rolls up to 300 mm diameter (optional winding device available for take-up after marking).
Fully compatible with laser films (ablation films, colour change films) for maximum contrast and precision.
Laser extraction system included, with control line and suction hose for clean, safe processing.
Flexible hardware setup: available with desktop or industrial PC control depending on requirements.
Exhaust and filtration options ensure compliance with safety and environmental standards.
Properties
Unlike conventional printing methods like pad printing and thermal transfer printing, there is no limit on the size and shape of the labels. Any 2D contour that you care to think of is possible. Laser-marked labels are resistant to the effects of temperature, abrasive wear, chemicals and atmospheric influences. Colours and writing do not smudge or fade. The strong adhesion of the special films provides excellent protection against warranty fraud and counterfeiting. Additionally, predetermined breaking points ensure that the labels cannot be completely removed and will tear if an attempt is made to remove them. The FoilStar is suitable for large-scale production and large batch sizes.
Software
The laser system is controlled using our proprietary Magic Mark marking software. This software enables workpieces to be marked with text, graphics, codes (data matrix codes, barcodes), serial numbers and logos. It can also be used to achieve uniform markings around the perimeter of workpieces with rotational symmetry. An intelligent user privilege management system facilitates the creation of different user groups. This way, the laser system can be adjusted to cater for the user’s specific requirements. When using the laser system in automated production lines, fully automated operation – including data exchange with various data sources – can be achieved without any difficulties. Optionally, plugins such as the code or script module can be used to add extra functions to the Magic Mark software.
Features and optional accessories
By strategically configuring the parameters, the laser beam is able to ablate extremely thin top colour layers on the film to reveal the contrasting colour layer underneath. In a second step, the finished film can be severed using the integrated cutting blade. Once it has been finished, the label can be removed from the backing and affixed to the workpiece.
Films and label
Laser films are an alternative for materials that are difficult or impossible to mark directly. Ablation films developed specifically for laser marking consist of multiple layers: A base layer, a film with adhesive layer, a contrast colour layer and a top colour layer. The laser beam initially removes the top colour layer, revealing the contrast colour layer underneath. In a second step, the laser system can cut through the entire film. This enables any possible 2D image to be reproduced as a label. The completed label can be effortlessly separated from the base layer following processing.
Colour change films, unlike ablation films, have a transparent laminate layer. This prevents gases and dust leaking out during the marking process. The marking is created under the laminate layer and can feature just as much contrast as ablation films.
Laser films are used on a huge scale as information media suitable for industrial applications. They have become indispensable for the vehicle industry in particular. Due to the huge quantities used, it was necessary to develop a process enabling these films to be marked with high contrast in short cycle times.
Controlling the FoilStar using Foil Manager
The film transportation and marking processes are controlled using the Foil Manager software included with FoilStar. Two versions of Foil Manager are available:
Semi-automated operation
Fully automated operation
Compatible Accessories
Tool reader
Software connections
Laser extraction systems
Laser safety
Magic Mark
Contour Tool
Data Import plugin
FoilStar plugin
GS1-Generator
OCR Plugin
Ruler Scale plugin
Unlimited design flexibility — Labels of any contour or layout can be produced, from simple text to complex graphics.
Industrial durability — Laser-marked films resist fading, smudging, and removal, ensuring permanent identification.
Security against tampering — Special adhesive films tear upon removal, preventing fraudulent label transfers.
Software integration — Controlled via Magic Mark and Foil Manager, enabling semi-automatic or fully automated workflows.
High throughput — Optimised for large batch sizes and short cycle times, meeting the needs of automotive and industrial sectors.
Customisable operation — Supports fixed templates, batch processing, and data import from Excel or XML for dynamic label content.