We have seen several types of barcode and QR Code labels on raw materials and finished goods, trade items, etc., haven’t we? But you might have also come across a distinct type of barcode/marking, engraved in some item, say a metal pipe, an automotive part, etc. This etched code is known as Direct Part Marking (DPM).
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What is DPM?
DPM is a method for embedding traceability directly into the part, not on a label that can peel, fade, or be lost, but into the part itself.
Put simply, DPM means permanently marking a manufactured part or component directly on the part surface (metal, plastic, ceramic, etc.) with a machine-readable code (barcode or 2D code, typically a 2D “matrix” standard such as a Data Matrix or sometimes a QR Code).
The mark is “indelible”, meaning it’s etched, engraved, dot-peened, laser-marked, chemically etched, or otherwise inscribed, not merely printed or affixed as a sticker. The DPM contains unique product-related information. It can include serial numbers, part numbers, manufacturing dates, batch codes, unique item identifiers, etc. DPM makes each part uniquely, reliably identifiable for its entire service life.
Why is DPM used?
Using traditional purchased barcode labels or adhesive tags is fine for many consumer goods. But in many industrial or high-value use cases, labels have serious drawbacks.
DPM, on the other hand, addresses those issues and offers:
1.Durability & permanence
Because the code is etched into the part, it survives harsh environments; extreme temperatures, chemicals, vibration, abrasion, painting/coating, cleaning, long-term wear and tear. It offers durability than other types of labelling.
2. Anti-tampering /Anti-counterfeiting
Since the code is part of the part itself, it cannot be easily removed or replaced (unlike a label), making it much harder to counterfeit or substitute parts. DPM on automotive spare parts is crucial and ensures that the right parts are assembled during car manufacturing, and parts are genuine, verifiable by the end customers when spare parts are needed.
3. Reliability of identification over the full lifecycle
Parts manufactured and assembled may go through many stages: production, assembly, supply chain, usage, maintenance, and repair. Over months or years, labels may degrade; DPM stays intact.
4. Traceability, compliance, and accountability
For regulated industries (automotive, aerospace, medical devices, defence), having an indelible part identifier helps with audits, recalls, warranty claims, and regulatory compliance. For example, certain defence standards require permanent physical markings.
5.Space constraints and small parts
Many components are small, curved, or have irregular surfaces where a label won’t stick or won’t fit. A DPM code (e.g., Data Matrix) can be very small and still hold enough data.
How DPM Works? DPM Methods
There are multiple ways to apply DPM. Common marking methods include:
1. Laser marking/laser etching/engraving
A focused laser beam vaporizes or alters the surface to create a mark. This method is highly precise, fast, and works on metals, plastics, ceramics, glass, etc.
2. Dot-peen marking (micro-percussion/dimpling)
A stylus repeatedly impacts the surface to create a pattern of small dots forming the code. Useful for metals, particularly when deep or robust marks are needed.
3. Chemical etching / electrochemical etching
Material is removed chemically to create marks; it is often used for metals.
4. Other methods
Embossing/indentation, scribing, ink-jet (less common for permanent marking), molding/casting with memory of part codes, etc.
When selecting a method, engineers consider the material and surface finish (polished metal, rough cast metal, plastic, ceramic?). The geometry and size of the part, flat, curved, small, or large, is also important. Small or curved surfaces make Data Matrix encoding more attractive, but may require careful process tuning. If a part will be exposed to heat, chemicals, paint, abrasion, or long-term outdoor/industrial exposure, that argues for deeper, more durable marking (laser, dot-peen). Also, some industries or customers may require marking to meet standards (for example, aerospace, defence). Because DPM codes are etched rather than printed (so contrast is often low, surface glare or reflectivity may be high, or marks may be shallow), reading them reliably requires specialized scanners or imagers (not all barcode scanners will read DPM properly).
DPM-Capable Scanners & Industrial Scanning
To leverage DPM, you need scanners/imagers capable of reliably reading DPM codes (with their lower contrast, etched/dotted surfaces, possible curvature, material reflectivity, etc.). Several industrial scanners on the market are purpose-built for DPM, including:
a. Zebra DS3600-DPA
b. Zebra DS3600-DPX
c. Zebra DS3600-DP
These are “industrial-grade” DPM-optimized, ultra-rugged scanners in Zebra’s 3600 series (with popular models like DS3608-DP / DS3678-DP), specifically designed to reliably capture DPM codes even on rough, low-contrast, curved or reflective surfaces, in dirty or harsh industrial environments.
Apart from these handheld scanners, Zebra Technologies also offers fixed industrial scanners that can easily scan DPM engravings.
a. Zebra FS42 Industrial Scanner
b. Zebra FS20 Industrial Scanner
c. Zebra FS10 Industrial Scanner
DPM in Industry 4.0
With the shift toward Industry 4.0, which means digitization, automation, data-driven operations, and full lifecycle management, DPM plays a strategic role.
Here’s how businesses benefit:
a. Each part gets a unique, permanent identifier; that identifier can be tracked from raw material to manufacturing, assembly, quality control, supply-chain, delivery, maintenance, and even disposal. This supports the "digital thread" and "digital twin" concepts of Industry 4.0.
b. Using DPM codes + industrial scanners, data capture becomes automatic and reliable; no manual entry of part numbers, no misreads, no labels that fall off or degrade. That improves quality, reduces rejects, supports just-in-time manufacturing, predictive maintenance, etc.
c. In regulated industries (automotive, aerospace, medical, defence), DPM helps meet audit, regulatory, and standardization requirements. It ensures that every part can be traced, inspected, and if needed, recalled or serviced.
d. Because the mark is permanent and hard to replicate or tamper with, DPM helps prevent counterfeit or unauthorized parts from entering the supply chain; critical for safety-critical industries.
e. Eliminates the need for labels (cost, waste, rework), reduces downtime, improves throughput. Enables lean manufacturing and efficient inventory/asset management.
f. For products that have long lifetimes (e.g., automotive parts, aerospace components, heavy machinery), DPM allows precise identification for maintenance, history tracking, warranties, and recall.
Key Industries that Benefit from DPM
Because of the combination of permanence, traceability, resilience, and compliance, DPM has become the de facto standard in many heavy industries:
a. DPM in Automotive
Components like engine blocks, transmission parts, chassis components, etc., are often critical for safety and require full traceability from manufacturing through assembly, supply chain, and service/maintenance. DPM ensures each part is uniquely and permanently identifiable.
b. DPM in Aerospace & Defence
Parts need to survive decades of service, exposure to heat, pressure, and maintenance cycles. For regulatory and safety reasons (e.g., lifecycle traceability, recall potential), DPM is indispensable.
c. Electronics / Precision Manufacturing with DPM
Small components, PCBs, molded plastic parts, often tiny, delicate, and requiring serialization or traceability. DPM (especially laser marking or etching) allows small yet machine-readable codes.
d. Medical Devices, Surgical Instruments with DPM
Where sterilization, cleaning, exposure to chemicals, and long life cycles are norms. Permanent marking ensures traceability, provenance, recall capability, and compliance with medical/device regulations.
e. Industrial Machinery and Heavy Equipment
Spare parts, replacement parts, maintenance, DPM ensures every part is tracked over decades, reducing errors, improving maintenance, and enabling detailed service logs.
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What’s Next for DPM -Trends and Future Directions
1.Deeper integration with Industry 4.0 / IIoT / digital-thread and digital-twin architectures.
2. Improved scanning, vision, and verification technologies.
3. Standardization & compliance growth.
4. Adoption in more sectors, high-end consumer goods (luxury watches, tools) for authenticity, warranty tracking, anti-counterfeiting, and quality control.
5. Cost reduction and automation of the marking process.
6. Linking DPM with digital/serial databases, blockchain, and lifetime data.
To summarize, Direct Part Marking (DPM) is a deceptively simple but powerful idea: instead of sticking a barcode label on a part, permanently embed the code into the part itself. That simple shift has huge implications for traceability, durability, reliability, compliance, and ultimately for how modern manufacturing (especially under Industry 4.0) is done. For industries like automotive, aerospace, electronics, medical devices, and heavy machinery, DPM has already become standard for parts marking.
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