World's first laser perforator -- a new paradigm
  Announcing the World's First Laser Perforator for Music Media

Over the last several days, there has been much discussion and
speculation about perforating music rolls with a laser.  There has also
been considerable discussion about the economics of roll perforating.

In another message entitled "The New Economics of Roll Perforation -
A contrarian view" [indexed as "Piano Roll Business Economics &
Technology"], I described what I believe are the realities of the roll
market for today -- and they are very different from those of yesteryear.
I also described a new kind of custom roll cutting business, capable of
producing single, custom-cut copies of practically any roll in any
format quickly and economically, while maintaining _no inventory_.

This seemingly-impossible, almost Utopian ideal is made possible by
three major, interlocking components:

1) A practical computer-controlled laser perforator for music rolls,
capable of a single copy of any roll in any format without retooling
of any kind.

2) Widespread preservation of music roll content in computer-readable
form via optical roll scanning.  Optical roll scanning has the benefit
of being extremely accurate and completely format-independent, unlike
discrete-sensor, tracker-based, switch-based or pneumatic scanners.

3) Direct MIDI to punch capability (also BAR/ANN to punch capability)

Items 2 and 3 are not too surprising.  Roll scanning has been around
for quite some time, and large-scale preservation is just around the
corner.  Two omni-format roll scanners capable of scanning any music
roll (or book) medium up to 22" wide are currently under construction.
The BAR/ANN format has been around for some time, and MIDI-to-punch
capability exists.  Obtaining item 1 is the key.

Let the speculation end!

The world's first laser perforator for music media already exists.
It is based upon a commercial laser engraver, will the full endorsement
and cooperation of the laser manufacturer (i.e., full manufacturer's
warranty intact!).  I have been quietly designing and building it
over the last several months and the prototype is nearing completion.
I have just applied for a U.S. patent on the basic techniques.

The first unit is already committed to private use and will not be
available for commercial production of music rolls, but I will build
additional units for anyone who wants one as soon as the prototype is
fully debugged and delivered.  If you are still interested in acquiring
one after reading the rest of this message, please contact me
privately.

A laser perforator is an extremely flexible and powerful machine; much
more flexible than any mechanical perforator.  It can do many things
that were previously impossible.  Without going into too much detail,
here are some of its capabilities (the list is far from complete!):

 - accept inexpensive standard size bulk paper rolls of any width
     up to 24"
 - slits paper to width as it perforates
 - effective punch step as small as 0.001"
 - perforation accuracy to 1000 ppi
 - can punch ANY format, any width -- without retooling or swapping
     parts
 - can simulate any punch shape or size (round, square, oval --
     anything)
 - mixed punch sizes/shapes on same roll (e.g., snake bite)
 - can cut two 11.25" rolls simultaneously from 24" wide paper.
 - can cut two mixed-format rolls at the same time
 - can cut the leader taper
 - can cut face-up or face-down, head-first or tail-first
 - roll info can be laser-stenciled onto leader and/or trailer
 - can cut media of virtually any thickness, including book music
     media and thick media like Regina Sublima rolls
 - automatic "bridging" (as necessary)
 - bridging "rules" can be altered

About the only real limitation is that it cannot cut multiple
thicknesses of paper (combustion hazard).  It can, however, cut two
rolls side by side, and with the right attachment (tandem cutting),
there is no time penalty.

For single thicknesses of paper, fire is not a risk.  Creative
ventilation, air-assist nozzle placement, and close monitoring of the
ventilation temperature and flow prevent the buildup of combustible
gases at the cutting site (although the laser manufacturer does not
recommend leaving the machine completely unattended).

Power consumption is less than 700 watts (not including the
ventilator).

The quality of cut is superb!  Hole edges are extremely clean and
precise, with no visible scorching of the hole edges.  There are no
torn edges, and no "scalloping", although the machine can even be
programmed to produce simulated authentic "scalloped" perforations
if that is what you desire (at a cost of some cutting speed).  I use
a vector-cutting approach as opposed to raster cutting (although the
patent covers both raster and vector cutting).  It is _much_ faster
to vector cut than to raster-cut (by about 20 to 1).

In the future, I will add an inkjet print head (or similar) to the
paper path for lyric printing, which should more or less round out
the capabilities of the machine.

Comments, questions?

Best Regards,
Gene Gerety

 [ Congratulations, Gene!  How fast will the machine cut a typical
 [ Duo-Art roll, feet (or meters) per minute?  -- Robbie