APPLICATION BRIEF

DIRECT PART MARKING

A GUIDE
THE NEXT GENERATION OF DIRECT PART MARKING (DPM)

Direct Part Marking (DPM) is a process by which bar codes are permanently marked onto a variety of materials.
The DPM process allows for marked materials to be tracked throughout their lifecycle, especially products slated for use in harsh environments.
DPM is used in a variety of industries, such as automotive, aerospace, weapons, manufacturing and electronics. Additionally, some national
departments of defense demand physical marks to be embedded on certain assets.
DPM has been successfully used on many different types of material, ranging from hard materials like metal, plastic, and glass, to soft materials such
as rubber and leather. The parts being marked can be as large as the engine block of a car, or as small as a medical instrument or fine jewelry.

DPM SYMBOLOGY

The most common barcode symbology to use with

DPM is DataMatrix. This is an industry standard, first
codified by AIAG (Automotive Industry Action Group).
Specifically, the ECC 200 subtype of DataMatrix
should be used. Why? The ECC 200 DataMatrix
(a 2D or 2 dimensional bar code) marks utilize the
Reed-Solomon Error Correction algorithm, which
provides a predetermined and predictable amount of
error correction capability. Error Correction capability
is especially important in DPM applications as the
objects being scanned are often naturally finished in
rough surface conditions, marred by dirt, rust and other

contaminations, and subjected to severe environments,

abrasive working conditions, and/or rough handling.
The superior error correction ability provided by ECC 200
allows DataMatrix barcodes with severe damages to
be decoded.
If the part to be marked is cylindrical in shape, it
may be better to choose a rectangular DataMatrix,
and to align it so that the longer direction is parallel
to the axis of symmetry. Most bar coding software/
hardware automatically generates square DataMatrix
barcodes, but is also capable of generating rectangular
DataMatrix if so specified.
PAGE 1

WHY 2D BAR CODES?

Consume less space
Have built-in error correction (100% data
recovery with 15 to 20% damage to symbol)
Have large data capacity (hundreds of data
characters are possible within each code
see figure below)
May be printed on paper labels to affix to a
surface or as directly applied marks (e.g., laser
etched onto a surface, peen stamped onto a
surface or ink jetted onto a surface)

Due to their small size and the amount of data

that can be stored on them, 2D bar codes can
enable manufacturers to:
Provide traceability - for the primary purpose
of precisely identifying manufactured items
involved in a spill or potential field action.
Provide verification and error proofing - the
capability to validate correct part/component/
module/assemblies
Provide part identification - the capability to
identify part/component/module/assemblies

2D CODES CAN CAN HOLD LARGE AMOUNTS OF DATA BY CARRYING

INFORMATION IN BOTH HORIZONTAL AND VERTICAL DIRECTIONS

APPLICATION BRIEF
DIRECT PART MARKING - A GUIDE

DOT PEENING

A machine (known throughout the industry as a

dot-peening machine) uses a sharp tool (the peen) to
impinge on the part being marked repeatedly, at precise
locations. Each module to be marked is represented by
an indent on the part.
Dot-peening is especially suitable to marking metal
parts. The peening of a metallic object does not
break the metallic bonds between atoms; rather, it
only deforms the bonds, and possibly increasing their
strength. An example of a peen mark is shown below.

LASER MARKING

Lasers can also be used to create marks on some

materials. This is done by directing a beam of coherent,
collimated, focused light energy onto an items surface.
In general, when a lasers beam comes into contact with
an item, its light energy is converted into heat energy,
which creates a mark either by melting, ablation, carbon
migration, or chemical reaction. Various materials may
react differently to each type of laser and/or laser
marking technique. All lasers will not create readable
marks on all substrates.
When considering a laser marking system, the following
factors should be taken into consideration:
The type of material to be marked (laser etching is
most commonly used on electronic components and
on metal medical devices)
The laser type and marking process type
Laser power
Cycle time
Information (volume of data) to be marked
Laser safety

Different materials absorb or reflect specific laser wave

lengths at different rates. The amount of absorption is
directly proportional to the lasers ability to heat the
material and cause a change in its appearance. The type
of lasering medium will determine a lasers light wave
length. Laser marking systems typically derive their name
from their lasing medium. For example, CO2 lasers use
carbon dioxide gas as a medium. Laser marking generally
produces the fastest marking cycle. An example of a laser
mark on stainless steel is shown below.

The marking parameter that affects the decode-ability

the most is the pitch. This is distance between nearest
modules. When choosing the pitch, one should consider
the surface roughness of the part to be marked and
the accuracy of the marking device. With rougher part
surfaces, and/or less accurate marking device, the pitch
should be chosen larger, in order to avoid ambiguities.
(Sometimes people use the term module size to refer
to the pitch. While these two values should coincide for
DataMatrix printed on paperand even then they may
not be the same due to an effect commonly referred to as
ink spread, in DPM they are generally very different.)
When the part surface is rough, it is sometimes
advantageous to mark it with a sharp peen (one with
a smaller cone angle), and to scan it at a large off-axis
angle. This helps the scanner to distinguish between
features created by the marking process from those that
existed originally before marking.
Sometimes it is necessary to paint a part after the
marking process. If this is the case, the marks may need to
be created with larger pitch and depth, so that the marks
are not completely covered up by the paint.
To benefit from the widest range of DPM scanners, it is
beneficial to choose the pitch value to be not too large,
nor too small, such as in the range of 6.7-20 mils. Some
scanners that scan DPM in this range of pitches can scan
normal-sized paper barcodes, providing efficiency and
economy at the same time.
PAGE 3

APPLICATION BRIEF
DIRECT PART MARKING - A GUIDE

MARKING GUIDELINES
Data elements must be larger than the surface
irregularities
Marking surface dictates minimum cell size
Different for every surface condition it is important
to note that there is no definitive set size for the
materials intended to be marked with DPM the
general rule is to create a mark as large as the size
your material will permit.
Similar for different marking techniques
Reference AIAG B-17 Direct Parts Marking Guideline
see the link to this Guideline at the end of this paper

Consider marking cycle time - cycle marking time for

better quality applies only to laser marks. Generally
longer marking time may mean a better mark but that
may not always be the case. Too long a cycle time
may burn or destroy a surface. Too short a cycle time on
a specific surface may make a mark unreadable.

Others it is important to take other marking guidelines

factors into consideration, such as ensuring there is
proper contrast between the actual mark and the
material that is being marked marks should be clearly
defined so they can be easily and efficiently decoded.
Another factor is to ensure the code is as visible as
possible to enable a successful decode a good practice
is avoiding creating marks too close to the edge of the
material being marked as much as possible.

CONSIDERATIONS

The following are typical criteria for using DPM

The part is too small to be labeled with traditional
bar code labels
The part is subjected to environmental conditions
that preclude the use of labels
DPM may be more cost efficient than individual
item labels
Identification is required for the life cycle of the
part and labels are not acceptable (for the reasons
stated above)
DPM is integrated as part of the manufacturing
process rather than a secondary or manual process

WHAT ARE SOME DRAWBACKS

OF DPM CODES?
A 2D code is difficult to read
The MOST common issue when a 2D code is difficult or
hard to read is that it is not printed properly.
In this case, end users typically blame the DPM reader,
but in most cases the real culprit is the code itself.
The best way to determine if a code is properly printed
is to use a DPM verifier to grade the code to determine
its quality. A DPM verifier is a system consisting of
lighting, optics, camera (imager), verification software,
and calibration references. The resolution of the
verification system should be at least twice that of the
imager (reader). This may be accomplished with either
higher magnification optics or an imaging device with
twice the resolution of the reader. As a good practice,
DPM systems should require verification immediately
following the creation of the mark to maintain quality
and downstream scan-ability. When encountering a
hard to read DPM code, the best way to determine its
readability and repeatability is to get a verifier and
grade the code. Verification grades fall between A,
B and C (good readability) to D, E and F (difficult to
read). The verifier looks at a number of criteria when
determining a grade. These examples of grades and
criteria are shown below.

SOLUTION BRIEF
MIGRATE YOUR NETWORK TO SECURE YOUR COMMUNICATIONS FUTURE

TIPS TO
ENSURE GOOD
DPM MARKS

GUIDELINE MARKING DPM

ON A CURVED SURFACE

1. To allow for the best possible imager

performance, it is best to use the

largest practical size element/cell
dimension that fits within the
available area.

2. Make the 2D symbol as large as

practical, not as small as possible.

As symbol element/cell size decreases
printing/marking and scanning/imaging
issues increase exponentially.

3. Datamatrix reading requires a quiet

zone in an area around the entire

perimeter (all four sides) with a quiet
zone size larger than the size of an
individual element within the code.

4. For marking and reading, flat surfaces

are preferred over curved surfaces.

The curvature of an item may prohibit
proper labeling or marking and may
distort the code to the point that it
cannot be decoded. If the label or mark
is on a round/curved surface, the
symbol height SHOULD be < 16% of
the parts diameter.

IMPROPER MARKING

PROPER MARKING

THE 2D CODE GRADES WELL, BUT

IT STILL CANNOT BE READ

If you have a DPM code that you are having problems

with but still cant read it dependably, it is possible that
the operator is at fault. DPM readers from Motorola
Solutions are among the best readers on the market and
are almost always not the problem. It is important to
remember that DPM is NOT like a barcode label. On a
paper label a 2D code usually has black dots printed on
a white surface which makes it easy to read. A 2D code
printed on a non-paper surface has all kinds of issues
that make it harder to read than a label. Among these
issues are:
2D Code Marked on Rough Surface
Solution: Read at an angle and at a distance far enough
that the imperfections are not interfering or as an
option on laser marked items, mark the 2D code after
first performing a clean up pass with the laser to
remove surface imperfections.
2D Code Marked on a Shiny Reflective Surface
Solution: Read the code in a way so that other light
sources and the reader do not cause the 2D code to
be washed out by unwanted lighting. First look at the
code with your eyes to try and see if ceiling lighting
or outside lighting cause a light bar to reflect back
from the source effectively rendering the visible code
from being seen. Minimize or eliminate this effect
by eliminating these reflections. Adjust your reader
position so that it is at angle that will not cause another
reflection from the readers light. Reflections back to the
reader from the reader lighting itself causes blinding
and prevents the reader from seeing the 2D code.
Focal Distance is too Close or too Far for Reader
to Read the Size of 2D
Solution: Start with the reader closer to the 2D code
and slowly move away until focus is correct and the 2D
code reads.

APPLICATION BRIEF
DIRECT PART MARKING - A GUIDE

Trying to Read the 2D Code at too Great or too

Small an Angle
Solution: Start with an angle that is about 75 degrees
to vertical and slowly move toward an angle of about
30 degrees to vertical (closer to parallel) while pulling
trigger at each position. If you have proper focus the
code will likely read.
Surface Imperfections Showing at Certain Angles
Degrades or Hides the 2D Code from the Reader
Solution: 2D codes marked on a surface where
machining marks create small long lines of imperfection
can be very difficult to read. Light from a reader bounces
back off these lines when presented at an angle that
is perpendicular to the grooves. Turn the part at an
orientation where the grooves are parallel to the reader
lighting. This hides the grooves as the lighting does not
bounce back to blind the reader, rather it simply renders
the grooves invisible to reader since the lighting does
not reflect back.
Not Enough Lighting to Enable the Reader to
Effectively See the code
Solution: There are times when the reader does not

elicit enough illumination to effectively allow the reader

to see the code. In these cases it may be necessary
to add external lighting to the reading surface to
provide enough contrast for the reader to see the code.
Sometimes ceiling lighting alone may help. Other times
you may have to add external focused LED lighting.
Peen Marked Codes that are Painted over are
Hard to Read
Solution: On Motorola DPM readers, painted over peen
marked codes that have good depth are easy to read
regardless of the color of the paint covering the code.
A low attack angle with the reader causes light from
the reader to bounce off the non-marked surface and
to reflect back over marked surfaces (the dots). The
reader sees what we call dark field illumination on the
surface which means surface is dark and the dots reflect
back light, which the reader sees as white dots. With
this method, it is very easy to read a completely black
painted over peen mark if there still are depressions on
the surface where the dots are.

APPENDIX
International Organization
for Standardization Site
(purchase required)
AIAG Direct Part Marking
Guideline (purchase
required)
Link to Motorola Solutions
DPM At A Glance Brochure

MARKING EXAMPLES
Laser Mark on Rough Surface with Clean Up Pass

Laser Mark on Rubber

Peen Mark on Cast Surface

Painted Over Peen Mark Shows How Dots light up

from Angle Lighting

Peen Mark on Hard Plastic

Rectangular Laser Marks on Shiny Curved Surface

Part number: AB-DPM_GUIDE. Printed in USA 10/12. MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M
Logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other
trademarks are the property of their respective owners. 2012 Motorola Solutions, Inc. All rights reserved. RO-4-2104