DEPARTMENT OF THE NAVY

ITEM UNIQUE IDENTIFICATION

(IUID) MARKING GUIDE:
APPLYING DATA MATRIX
IDENTIFICATION SYMBOLS
TO LEGACY PARTS

SEPTEMBER 2011
Version 1.1

DEPUTY ASSISTANT SECRETARY OF THE NAVY

(EXPEDITIONARY PROGRAMS AND
LOGISTICS MANAGEMENT)
WASHINGTON, D.C. 20350-1000
 DON IUID Marking Guide

RECORD OF CHANGES

Version Page Date Description

1.0 All 12/07/2010 First Version
1.1 All 9/23/2011 Incorporated technical
and editorial
clarifications

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 DON IUID Marking Guide

FOREWORD

This Department of Navy Item Unique Identification (IUID) Marking Guide provides
technical information for applying IUID data matrix symbols to legacy items owned by the
Department of Navy (DON). It is intended to support better decision-making by DON marking
managers, engineers, and implementers. The information contained in this guide is derived from
Department of Defense (DoD) standards, International Standards Organization (ISO) standards,
industrial organizations, and practical experience.

IUID marking of qualifying items is required by Defense Federal Acquisition Regulation

Supplement (DFARS), and DoD and SECNAV Instructions (referenced in Appendix A). This
guide does not repeat requirements; therefore, PMs and their staffs should refer to all referenced
documents, and other resources such as organizational websites for overall IUID implementation
planning and monitoring requirements. This guide is intended to reduce the time required by
PMs and their staffs to understand the technical dimensions of planning an IUID marking effort
and increase the quality and compliance of the mark symbols upon application within the
framework of a larger program implementation plan.

The guide captures the expertise of many years’ work by the IUID Center at the Naval Surface
Warfare Center (NSWC) Corona in applying, testing, and consulting on IUID data matrices. It is
not intended as directive, but shares the IUID Center’s insights with the widening community of
personnel involved in IUID marking to promote longevity and readability of marks.

We support efforts to improve this technical information and its accessibility to decision-makers
at every level, and encourage recommendations to enhance the usefulness of this guide. Marking
technologies, materials, and devices are constantly evolving, so your experiences could be
helpful in improving this guide. Your recommendations may be made to NSWC Corona’s IUID
Center at: [email protected]; or to the DASN (Expeditionary Programs and
Logistics Management) IUID policy staff at [email protected]. Comments may also
be submitted to:
DASN (Expeditionary Programs and Logistics Management)
1000 NAVY PENTAGON
WASHINGTON DC 20350-1000

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Contents
1 Introduction ............................................................................................................................. 1
2 Background ............................................................................................................................. 1
3 Organization............................................................................................................................ 2
4 Scope ....................................................................................................................................... 2
5 Permanent Data Matrices ........................................................................................................ 3
5.1 Marking Process Design................................................................................................... 3
5.1.1 Policy Options for Engineering Change Requests and Drawing Revisions ............. 3
5.1.2 Placement of the Mark .............................................................................................. 3
5.1.3 Readable Marks ........................................................................................................ 4
5.1.4 Minimizing Attachment Failures .............................................................................. 6
5.1.5 Choosing the Right Marking Method ....................................................................... 6
5.2 Proper Execution of the Marking Process ........................................................................ 7
5.2.1 Production Quality of the Mark ................................................................................ 7
Appendix A. Applicable Documents .............................................................................................. 8
Appendix B. Intrusive Marks........................................................................................................ 10
Appendix C. Policy for Conditional Exceptions to Engineering Analysis .................................. 11
Appendix D. Strategies for Minimizing the Impacts of Non-Recurring Engineering ................. 12
Appendix E. Marking Location and Surface Finish Information ................................................. 13
Appendix F. Data Matrix Module Size by Environment .............................................................. 18
Appendix G. Cell Size Limits & Techniques to Overcome Size Limits ..................................... 19
Appendix H. Surface Preparation ................................................................................................. 22
Appendix I. Marking with a Label................................................................................................ 24
Appendix J. Marking Techniques Overview ................................................................................ 27
Appendix K. Additive Marks........................................................................................................ 31
Appendix L. Common Part Marking Methods ............................................................................. 32
Appendix M. Removal of Data Matrix Marks .............................................................................. 33
Appendix N. Verification ............................................................................................................. 35
Appendix O. Quality Sampling Plans for Barcode Creation ........................................................ 37
Appendix P. Useful Process Control Techniques ......................................................................... 39
Appendix Q: Acronyms ................................................................................................................ 41

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1 In tro d u c tio n
The purpose of this document is to consolidate and present technical information needed to mark
legacy items effectively with Item Unique Identification (IUID) compliant two-dimensional
(2-D) data matrix symbols. 1
Information within this guide was created by representatives from the major Automatic
Identification and Data Capture (AI/DC) manufacturers, government, and aerospace user groups
under a collaborative agreement with National Aeronautics and Space Administration (NASA)
and the United States Coast Guard (USCG).
This guide is published by the Department of the Navy (DON), through the Office of the Deputy
Assistant Secretary of the Navy (DASN), Expeditionary Programs and Logistics Management
(ELM).
2 Ba c kg ro u n d
Many items within the DON inventory are required to be marked with a Unique Item Identifier
(UII) encoded into a two-dimensional (2-D) Error Correction Code 2 (ECC) 200 data matrix
symbol (Figure 1) per MIL-STD-130 (latest version), Department of Defense Standard Practice:
Identification Marking of U.S. Military Property.

Figure 1. ECC200 Data Matrix Symbol

The Department of Defense’s (DoD) IUID requirements dictate an item’s mark:
• Remains readable throughout the item’s normal life cycle
• Withstands all environmental conditions to which the item will be exposed under normal
operating conditions
• Provides no detrimental effects on the functional performance, reliability, or durability of
the item.
IUID markings applied to legacy parts should be made using non-intrusive marking methods
unless intrusive marking is specifically authorized by quality assurance, safety, and engineering
competencies of the relevant program. A non-intrusive marking method adds material to the
surface of the item either directly as with stenciling, laser bonding, or direct ink jet, or indirectly
as a label or data plate. An intrusive marking method either deforms or removes material from

1
Other documents explain facets of IUID not covered herein. See Appendix A for references.
2
ECC is known as Error Checking and Correcting by some.

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the surface of the item, as with dot peening, stamping, abrading, scribing, or etching.
While labeling is often the easiest method to implement, it may not always be the best solution.
To determine the best marking solution, the following factors about the item to be marked must
be considered:
• Function
• Available marking area
• Material type
• Color
• Hardness
• Surface roughness/finish
• Surface thickness
• Operating environment.
If it is determined that intrusive marking is required and such marking has been authorized by
quality assurance, safety, and engineering competencies for an item, then one or a combination
of the following may be required to safely mark legacy items:
• Appropriate engineering drawings and specifications
• Approved marking device settings
• Appropriate clamping fixtures
• Depth measurement and microscopic evaluation equipment
• On-site quality, safety, and engineering personnel to certify and monitor marking
operations
• Procedures to evaluate and disposition improperly applied markings
• Procedures to assess the cumulative effects of multiple marking removal and re-
applications.
There are a number of details and factors to take into consideration when selecting and utilizing
intrusive marking; the full discussion is beyond the scope of this document. An overview of
some common intrusive, direct part marking methods is presented in Appendix B.
3 Org a n iza tio n
This guide is organized as a relatively short body, supported by extensive appendices on
individual technical issues.
4 Scope
The information within this guide is provided for DON personnel and contractors to facilitate
identification of items using IUID compliant ECC 200 data matrix symbols. This marking guide
applies to DON organizations responsible for the use, maintenance, servicing, and/or storage of
legacy parts. This guide only applies to hardware owned by the Department of the Navy and

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does not authorize methods for marking hardware owned by other government organizations.
The guidance provided by this document may be referenced or incorporated into detailed
maintenance guides as approved by the item manager(s) responsible for the legacy items to be
marked.
5 P e rm a n e n t Da ta Ma tric e s
A foundational requirement within IUID policy is that its data matrices remain readable
throughout an item’s normal life cycle. Achieving this is a matter of designing and executing the
marking process properly.

5.1 Ma rkin g P ro c e s s De s ig n

Designing the marking process for legacy items requires familiarity with relevant policy, the
lifecycle environmental exposure, and intended use of the items, as well as a variety of
requirements for producing technically sound data matrix marks.

5.1.1 Policy Options for Engineering Change Requests and Drawing Revisions

Given the tremendous burden in terms of cost, workload, and scheduling associated with
engineering change requests and drawing revisions, it is useful to take advantage of the broad
scope found in DON policy. SECNAVINST4440.34 provides conditional exemption from
engineering change requests and drawing revisions when affixing labels and/or data plates for
IUID purposes (see Appendix C).
If conditions for the above exemption cannot be met, then alternative plans must be made. The
Guidelines for Engineering, Manufacturing and Maintenance Documentation Requirements for
Item Unique Identification (IUID) Implementation, version 1.2 provides different strategies for
minimizing the impact of cost, workload, and schedule associated with performing engineering
and updating technical documentation for IUID marking (see Appendix D).

5.1.2 Placement of the Mark

Where the IUID mark is placed on the item strongly influences the mark’s durability and
usefulness. Therefore, when determining where to place the mark, consider the following:
• Apply marks in protected areas when possible
• Apply marks on flat areas when possible
• The mark should be readable when the marked item is in-service
• The mark should be readable when the marked item is stowed
• Multiple identical marks can be applied to the same item.
Unless directed to the contrary by the technical authority, do not place marks/labels:
• On components or pieces authorized to be replaced during field maintenance
• Over vents and/or air intakes
• Over other information

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• Covering windows, view ports, access ports, or fastener holes

• Over seams between separable pieces of the item
• In direct air streams (for example, leading edge of wings, helicopter rotors, exposed
portions of turbine blades, and so forth)
• On sealing surfaces
• On wearing surfaces
• Near high heat sources
• Over lenses, optics, or sensors
• On surfaces with dimensional tolerance requirements
• On precision cleaned parts in hermetically sealed packaging.
Other placement considerations become important in specialized circumstances, such as when
marking curved, rough, or shiny surfaces or marking items that are sensitive to electrostatic
discharge. Many placement considerations stem from a technical understanding of how 2-D
barcode readers (scanners) decode symbols as well as understanding efforts taken to maximize
the reliability of decoding the data matrix. For information about mark placement on curved,
rough, or irregularly shaped items, see Appendix E.

5.1.3 Readable Marks

Understanding what makes a data matrix readable is helpful in achieving a permanent mark.
There are four basic categories of techniques to help make a mark legible:
• Make the individual cells (modules) of the data matrix large
• Make the dark parts as black as possible, make the light parts as white as possible
• Match the dimensions, as closely as possible, to the specification 3
• Protect the mark with a cover or coating.

5.1.3.1 Cell Size

The data matrix symbol is made from a collection of small black or white squares 4 called “cells”
or “modules.” It is easier to fatally damage a small data matrix than it is to fatally damage a
larger data matrix containing the same data. In other words, if a small data matrix is scratched,
the likelihood that matrix will be rendered unreadable is greater than if the same scratch were
made to a larger data matrix. Damaged symbols with large cell sizes are more likely to be
reconstructed by the decoding software. Consequently, cell sizes must be enlarged to overcome
damage anticipated in harsh manufacturing, operational, and overhaul environments. See
Appendix F for suggested cell sizes for different operational environments. For techniques and

3
The ECC 200 data matrix specification is documented in ISO/IEC 16022 Information Technology – International Symbology
Specification – Data Matrix.
4
Some marking methods, such as dot peening, produce small circles as opposed to squares.

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more general information to optimize module size see Appendix G.

5.1.3.2 Contrast

Dark colored markings are generally applied to light surfaces and light markings applied to dark
surfaces. The minimum contrast difference between the symbol and its substrate that can be
reliably read is 40% as shown on a typical gray scale comparator (Figure 2).

Figure 2. Mark/Substrate Symbol Contrast

The minimum acceptable contrast level difference is 20% at the point of marking to allow for
degradation over time in the operational environment. Care must be taken to apply marks in an
area of uniform color in situations where surface colors change (such as camouflage patterns).
AIM DPM-1-2006 mark quality verification requirements call for a minimum contrast level of
≥2.0 (C) or better.

5.1.3.3 Quiet Zone

A clear space (quiet zone) must be left around the outside of the symbol in order for the scanner
to successfully decode the data matrix. A minimum of one cell width of quiet zone must be left
around the symbol. However, due to variations in surface finish, it is helpful to extend this area.
If possible, allow an additional 10% of the longest symbol side.
Encroachment into the quiet zone occurs when (1) the data matrix is applied too closely to the
edge of the designated marking area; or (2) other information is applied too closely to the data
matrix (Figure 3). Both problems are shown on the right side of Figure 3.

Figure 3. Example of Proper and Improper Quiet Zone Allocation

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5.1.3.4 Protective Coatings and Covers

Protective coatings and covers can add resilience to marks by protecting the mark, substrate, and
possibly adhesive from light and/or chemical induced damage. The coatings and covers should
have a matte finish to minimize unwanted reflection off the surface. When using clear adhesive
labels, avoid trapping air bubbles between the cover and the mark.

5.1.4 Minimizing Attachment Failures

Failures of labels to maintain attachment to the item occur for a variety of reasons. In some
cases, the strength of attachment declines over time, while in other cases, the initial strength of
attachment is insufficient.
Attachment strength weakens over time due to the slow, persistent degradation of materials,
which can be caused by ultraviolet (UV) light, thermal expansion, or corrosion.
Adhesives/epoxies are often damaged by UV radiation. Choosing UV-blocking label stock
minimizes this failure mode. Rigid adhesives/epoxies physically degrade if attaching two rigid
materials to each other, which grow and shrink by different amounts as they heat and cool
(different materials almost always have different coefficients of thermal expansion). This is
prevented by using flexible adhesives/epoxies. Lastly, if two different types of metals are
attached to each other so that electricity can flow from one to the other, they will corrode over
time. This is a particularly serious problem for aluminum data plates riveted to large steel items.
Keeping the metals separated from each other with a non-conductive layer (often an adhesive
tape) prevents this problem.
Insufficient initial attachment strength is due to using marking materials ill-suited to the item’s
environmental requirements, or to the marking process. Therefore, select marking materials
based on the item’s environmental requirements as well as any maintenance procedures—both
authorized and unauthorized—to which the item is subjected. Adhesives and epoxies are at risk
of failure when they become brittle at low temperatures or soften at high temperatures, and they
break down completely if the temperature is high enough. Finally, improper surface preparation
(poor cleaning) leads to lower attachment strength and can be a prevalent, persistent, and perhaps
critical problem. For more information on surface preparation, see Appendix H. For more
information on the application of labels see Appendix I.

5.1.5 Choosing the Right Marking Method

As mentioned above, it may be possible to use established marking processes and procedures.
They are likely the best choice, providing these processes support the creation of a high-quality
data matrix symbol.
However, when a new marking method is required, a survey of methods and materials is
appropriate. Although marking technologies have existed for a long time, new materials and
techniques continue to emerge. For an overview of some of the available marking techniques see
Appendix J.
In general, intrusive marks are the most durable types of marks available. These marks also
prove to be the riskiest. They should not be used unless adding material to the item is
unacceptable. See Appendix B for more information.

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The next most durable marks fuse rugged material directly to the item’s surface to form the
mark. These additive marks vary in their inherent risks but can be nearly as durable as intrusive
marks. Available materials and application techniques continue to evolve rapidly in this area.
Many of the newest techniques and materials use lasers to fuse the mark to the surface. See
Appendix K for more information on additive marks. See Appendix L for more information on
common part marking methods.
Although applying labels is considered the least durable type of marking method, it should not be
considered inherently weak. As a case in point, Post-It-Notes® are likely the least durable type
of label, whereas a welded stainless steel plate could be among the most durable. The use of
labels, which are available in a variety of materials and can be applied using many different
methods, is often the cheapest and most convenient marking method available. See Appendix I
for more information.

5.2 P ro p e r Exe c u tio n o f th e Ma rkin g P ro c e s s

Proper execution of the marking process requires the information encoded into the data matrix be
both formatted correctly and applied to the correct item. Although independent software exists
to evaluate the formatting of the data matrix symbol to check it meets IUID requirements 5, most
verification systems validate a mark’s syntax at the same time as verifying the mark’s production
quality.
Ensuring IUID marks are placed on the appropriate items is a matter of training, proper
management, and faithful adherence to quality assurance procedures. Procedures should be
devised to correct items after they have been marked incorrectly. These procedures should focus
on detecting errors within 60 days because there is only a 60 day window of opportunity to
correct information sent to the IUID Registry. See Appendix M for information about how to
remove a data matrix mark from an item.

5.2.1 Production Quality of the Mark

DoD and DON policy requires the verification of IUID data matrix marks. Verification is the
process that checks the production quality of the mark—this is different from checking the
information encoded within the mark. See Appendix N for more details.
Verification can be performed on each data matrix or as part of a sampling plan. Appendix O
provides a workable sampling plan for IUID verification. It may be used in the absence of
direction to the contrary from the technical authority.
Verification of the symbol quality requires both specialized hardware (a verifier) and software.
Even so, there are a number of checks which can be done without a verifier to evaluate the
production quality of the mark. See Appendix P for details.

5
A useful example of syntax-checking software is the government-owned Quick Compliance Tool Suite available at
www.qcts.org.

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Appendix A. Applicable Documents

Government Documents
DFARS 252.211-7003 Item Identification and Valuation
DoD Dir. 8320.03 Unique Identification (UID) Standards for a Net-Centric Department of
Defense, March 23, 2007
DoD Guide Department of Defense Guide to Uniquely Identifying Items
DoD Guide Guidelines for Engineering, Manufacturing and Maintenance Documentation
Requirements for Item Unique Identification (IUID) Implementation
DoD Instr. 4151.19 Serialized Item Management (SIM) for Materiel Maintenance
DoD Instr. 5000.02 Operation of the Defense Acquisition System
DoD Instr. 5000.64 Accountability and Management of DoD-Owned Equipment and Other
Accountable Property
DoD Instr. 8320.04 Item Unique Identification (IUID) Standards for Tangible Personal Property
MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys
MIL-C-38736 Sealing And Coating Compound, Corrosion Inhibitive
MIL-DTL-15024 Detail Specification Plates, Tags, And Bands For Identification Of Equipment,
General Specification For (28 Nov 1997)
MIL-DTL-19834 Detail Specification Plates, Identification Or Guide, Metal Foil, Adhesive
Backed General Specification For (6 Jul 2006)
MIL-M-43719 Marking Materials And Markers, Adhesive, Elastomeric, Pigmented; (30 Sep
1992)
MIL-M-87958 Marker Blanks, Pressure Sensitive Adhesive Wire or Cable Marker and
Identification Label
MIL-PRF-61002 Pressure-Sensitive Adhesive Labels For Bar Coding
MIL-PRF-87937 Performance Specification: Cleaning Compound, Aerospace Equipment
MIL-STD-129 Department Of Defense Standard Practice Military Marking For Shipment And
Storage
MIL-STD-130 Identification Marking of U.S. Military Property
MIL-STD-810 Department of Defense Test Method Standard for Environmental Engineering
Considerations and Laboratory Tests
MIL-STD-871 Electro-Chemical Stripping of Inorganic Finishes
MIL-STD-975 NASA Standard Electrical Parts List
MIL-STD-1246 Product Cleanliness Levels and Contamination Control Program
NASA-STD-6002 Applying Data Matrix Identification Symbols on Aerospace Parts
NASA-HDBK-6003 Application Of Data Matrix Identification Symbols To Aerospace Parts Using
Direct Part Marking Methods/Techniques
NAVAIR 01-1A-509-1 Technical manual, cleaning and corrosion (volume I & III) corrosion program
(TM 1-1500-344-23-1) and corrosion theory
(TO 1-1-689-1)
SECNAVINST 4440.34 Implementation of Item Unique Identification Within the Department of the
Navy

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Non-Government Documents
A-A-208 Ink, Marking, Stencil, Opaque (Porous and Nonporous Surfaces)
A-A-1558 Commercial Item Description: Paint, Stencil
A-A-56032 Ink, Marking, Epoxy Base
AIM BC11-ISS AIM Specification For Data Matrix
AIM DPM-1-2006 Direct Part Mark (DPM) Quality Guideline
ANSI MH10.8.2 Data Identifier And Application Identifier Standard
ANSI X3.182 Bar Code Print Quality - Guideline
ASME/ANSI B46.1 Surface Texture, Surface Roughness, Waviness And Lay
ATA Spec 2000 Chapter 9 Automated Identification And Data Capture
ISO/IEC 2859-1 Sampling Procedures For Inspection By Attributes - Part 1: Sampling Plans
Indexed By Acceptable Quality Level (AQL) For Lot - By - Lot Inspection
ISO/IEC 15415 Information Technology—Automatic Identification And Data Capture
Techniques—Bar Code Print Quality Test Specification — Two-Dimensional
Symbols
ISO/IEC 15418 Information Technology—EAN/UCC Application Identifiers And FACT Data
Identifiers And Maintenance
ISO/IEC 15434 Information Technology—Syntax For High Capacity ADC Media
ISO/IEC 15459-2 Information Technology—Part 2: Registration Procedures
ISO/IEC 16022 Information Technology—International Symbology Specification - Data
Matrix
MBO295-005 Material Cleanliness Level, Precision Clean Packaging
SAE ARP 6002 Marking; Standard Hose, Aircraft-FSC 4720; Should Be Used Instead of
MIL-M-6002A, Which Was Cancelled on 1 November 1999
SAE AS9132 Data Matrix (2D) Coding Quality Requirements For Parts Marking
TT-L-50 Clear, Acrylic Lacquer Aerosol, Type II

The documents listed in this appendix may have been revised since publication. Check for the
latest version of the reference.

Useful Websites
DASN (ELM) IUID website:
https://acquisition.navy.mil/rda/home/acquisition_one_source/item_unique_identification_iuid

Director of Defense Procurement and Acquisition Policy website:

http://www.uniqueid.org

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Appendix B. Intrusive Marks

Intrusive marks are formed by casting, molding, or forging the mark into the part during
manufacturing or added after manufacturing by burning, engraving, etching, stamp impression,
vaporizing, and so forth. An intrusive mark is designed to last the life of the part and will
survive overhaul in many cases.
However, if intrusive markings are applied improperly, they can irreparably damage parts,
affecting function, or in some cases, degrade material properties beyond a point of acceptability.
Some intrusive marking processes, particularly visible wave length lasers, dot peen, and deep
electrochemical etch, cannot be approved for use in safety critical applications without
appropriate metallurgical testing.
Typical intrusive marking methods include:
• Abrasive blast
• Direct laser marking using short wavelength lasers
• Dot peening (stamp impression)
• Electrochemical etching (electrolytic surface coloring or metal removal processes)
• Engraving
• Fabric embroidery
• Laser shot peening
• Milling.
Direct Part Marking Engineering and Test Database
Extensive engineering and metallurgy test data are available to the government and public in the
“Direct Part Marking Engineering and Test Database,” to allow wide distribution of expensive
engineering results. The database contains many test results of different methods of intrusive
marking on different metals and surfaces. The test results can be accessed at:
http://rsesc.uah.edu/DPM.
Three considerations are addressed:
• IUID marking methods (dot peen, laser/ chemical etch, direct ink, label, engraving,
coating)
• Material types & finishes (80% common to most of industry – aluminum, titanium, steel,
copper/nickel)
• Environmental criteria (80% common to most of industry or use worst case - ultraviolet,
heat, cold, lubricants, humidity).
All DoD organizations conducting controlled tests are encouraged to submit their testing for
public availability in this resource. University testing facilities are available to interested parties
for additional testing on a cost basis.

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Appendix C. Policy for Conditional Exceptions to

Engineering Analysis
SECNAVINST 4440.34 of 22 December 2009 Section 5f:
“Engineering change requests and drawing revisions shall not be required when affixing labels
with IUID markings to legacy equipment if it does not impact form, fit or function and if the
following conditions are met:
(1) The existing label is completely removed.
(a) The new label with IUID compliant data matrix is placed in the same
location as the replaced label.
(b) The new label with IUID compliant data matrix has the same dimensions as
the replaced label.
(c) The new label material and method of marking is the same as the replaced
label or an improved and qualified media replacement. The IUID compliant
data matrix must be permanent, per MIL-STD-130N of 17 Dec 07.
(d) The new label is affixed on the item in the same manner as the replaced
label.
(e) The information on the replacement label may be resized or repositioned
anywhere on the label to accommodate [the] IUID compliant data matrix.
(2) A replacement label is not required if sufficient space exists to place the IUID
compliant data matrix or label to the right, left, up or down with respect to the
existing label.
(3) A replacement label is not required if room exists on the current label to add an
IUID compliant data matrix.
(4) When otherwise determined by the appropriate Technical Authority (TA) of the
respective organization.”
For configuration management purposes, the details of this replacement label must be conveyed
to the technical authority for later incorporation into the technical drawings for any item with a
technical drawing package.
For purposes of applying the policy above, the definition of “label” is below.
MIL-STD-130N section 3.34: (definition of Label)
Label. An item marked with the identification information of another item and affixed to that
other item. A label may be of any similar or different material than that of the item to which it is
affixed. A label may be made of a metallic or non-metallic material. Labels may be affixed to
the identified item by any appropriate means. Labels are often referred to as plates (i.e. data
plate, name plate, ID plate, etc.) however, label material and methods of marking and affixing
have no bearing on this distinction.

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Appendix D. Strategies for Minimizing

the Impacts of Non-Recurring Engineering
Excerpt quoted from The Guidelines for Engineering, Manufacturing and Maintenance
Documentation Requirements for Item Unique Identification (IUID) Implementation, version 1.2
published April 20, 2007
• Replacing/modifying existing data plates with UII labels. Existing data plate
documentation can be used. The current technical data already specifies the material and
placement of the data plate. Human readable data other than IUID information can exist
on the new data plate. The labels provide high contrast allowing interrogation of mark by
lower cost readers.
• Issuing a global engineering change notice. This would provide instructions on a single
drawing on how to mark qualifying items.
• Issuing IUID part-marking work orders into the existing manufacturing and enterprise
resource planning processes, which minimizes the need to change drawings.
• Changing company part marking quality standards to include IUID requirements.
• When the necessary marking information and criteria do not change the form, fit, or
function of the part, the change does not require an immediate drawing update, but rather
can be accomplished by a coversheet with the marking instructions, thus permitting
consolidation of drawing requirements.
• Direct part marking (DPM) will require more engineering analysis than labeling. The
main issue that necessitates additional engineering analysis for DPM is the fact that the
mark is made directly on the component rather then [sic] attached like a label. Wherever
possible, the engineering decisions for location and type of application should be made
on documented results from previous analysis. Currently NASA has taken the lead in
this area and their documentation has provided a wealth of information that has precluded
much of the testing that would normally be required when one marks directly into the
material of a component.

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Appendix E. Marking Location and Surface Finish Information

Symbol Shape
The data matrix symbol can be created as a square or a rectangle (Figure 4). The square is
preferred unless the marking area on the item is rectangular and limits the cell size of a square
data matrix. For some linear-shaped parts such as pipes, lines, narrow part edges, and so forth, it
is usually desirable to use a rectangular-shaped symbol; the intent is to use a symbol shape that
provides the largest cells.

Figure 4. Symbol Shapes

Sensitive Surfaces
Precision-cleaned parts (MIL-STD-1246) stored in hermetically sealed packages to maintain
cleanliness, as well as electrical, electronic, and electromechanical (EEE) parts (MIL-STD-975)
packaged to prevent electrostatic discharge (ESD), should not be marked directly. Identify these
items with labels attached to the exterior of the packaging.
Thin Surfaces
Part thickness is not usually a consideration in applying non-intrusive markings, with the
exception of laser bonding.
Curved Surfaces
Flat surfaces are preferred over curved surfaces for marking when a choice is available. A
rectangular symbol, rather than a square symbol, is better for application to polished concave or
convex cylindrical parts. The rectangle is sized to fit either within the reflective band of light
that emanates from the spine of the curve or on 5% of the circumference, as shown in Figure 5.

Figure 5. Proper Placement of Data Matrix Symbols on a Curved Surface

Under normal room light, this band of light typically occupies 16% of the diameter of the curve
but can increase in size under bright light conditions. To apply larger symbols, the surface
should be textured to reduce glare or matte-finished, laser-markable paints should be used to
mark the part.
Labeling Curved Surfaces
When applying a label to a one-dimensional curve (such as a cylinder), use dimensionally stable
label stock (for example, polyethylene) to reduce cell deformation due to stretching. However, if
the shape is a 2-D curve (like a ball), a dimensionally stable label material will develop creases
and wrinkles when applied and should therefore be avoided.
Labels that can stretch (such as polypropylene) should be applied with great care to minimize

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distortion to the cells of the data matrix. If possible, avoid the use of labels for 2-D curves. If no
alternative exists, verify the marks after application to ensure the mark is remains readable.
Verification can be used to check stretch-induced cell deformation when performed after
application rather than before.
Labels applied to curved surfaces using adhesives may “flag” (that is, the edges may lift as the
material resumes its normal, flat, geometry). Flagging occurs when the label material retains its
original shape but the edges were not sufficiently seated to the base material. Therefore, both
surface preparation and burnishing the label’s edges are important when working with curved
surfaces. Note also the use of softer, thicker adhesives help prevent flagging.
Surface Roughness/Finish
Surface roughness poses different problems depending on whether you are trying to apply a label
or are trying to apply the mark directly to the item’s surface.
Using adhesives almost always works better on smoother surfaces. When a smooth surface is
unavailable, thicker adhesive can compensate as can double-sided adhesive tapes.
Structural epoxies vary in their chemistry and are optimized for a specific surface roughness.
Matching the epoxy to the item’s surface roughness is an important consideration.
When applying direct surface marks, the symbol marking should be limited to surface roughness
levels averaging between 8 and 250 micro-inches [millionth of an inch (0.0000254 mm)] as
measured per ASME/ANSI B46.1. A typical surface roughness gauge is illustrated in
Figure 6. Surfaces that fall outside of acceptable surface roughness levels (Figure 7) can be
resurfaced as directed by engineering; coated with laser-markable paint that fills the recesses; or
marked with labels, tags, or bands.

Figure 6. Typical Surface Finish Roughness Gauge

Note: Data matrices in Figure 6 are not IUID compliant.

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Processing
Roughness Average (Ra) µin.
Method
1 2 4 8 16 32 64 125 250 500 1000 2000
Lapped
Ground
Blanchard
Machining
Shape Turned
Milled
Profiled
Nonabrasive ECM
Finishing EDM
LBM
Grit Blasting
Blasting Sand Blasting
Shot Peening
Die
Investment
Shell Mold
Centrifugal
Cast
Permanent Mold
Surfaces
Non-ferrous
Sand
Ferrous Green
Sand

Optimum Marking Range

Figure 7. Average Roughness by Surface-Finishing Method
Particularly smooth surfaces (0 to 8 micro-inches) are ill-suited for directly applied marks
because they are reflective. Light from a reader illuminating the mark will reflect off of the
surface in one direction (the direction depends on the angle of the reader relative to the surface).
If the light reflects back into the reader, it will be too bright and will make the mark difficult to
decode. If the light does not reflect back to the reader, the surface will appear dark to the reader
and make the mark difficult to decode.
Particularly rough surfaces, such as cast surfaces, present a unique symbol-decoding challenge,
because the surface irregularities (pits) create shadows that can be misinterpreted by the
decoding software as dark data cells.
Consequently, individual data cells in the symbol must be larger than the surface irregularities
(for the decoding software to differentiate between the two features). The data cells contained in
the symbol must be increased in size in direct proportion to the average surface roughness to
ensure successful decoding. Figure 8 provides a formula for calculating minimum cell size
restrictions to aid in determining minimum symbol sizes for cast surfaces. Table 1 provides the
calculated minimum readable cell size values for selected average roughness levels.

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Figure 8. Graph to Interpolate Minimum Cell Size for Rough Surfaces

Average Roughness Level Minimum Cell Size

(millionths of an inch) (inches)
20 (0.000508 mm) 0.0075 (0.19 mm)*
60 (0.001524 mm) 0.0091 (0.23 mm)
129 (0.003048 mm) 0.0150 (0.38 mm)
200 (0.005080 mm) 0.0201 (0.51 mm)
300 (0.007620 mm) 0.0252 (0.64 mm)
420 (0.010668 mm) 0.01299 (0.76 mm)
*0.0075 inches approaches the limits of many readers regardless of surface roughness

Table 1. Minimum Readable Cell Size by Roughness Level

An alternative to increasing symbol cell size is to coat the marking area to provide a smoother
substrate. Figure 9 illustrates the relationship between data cell size and cast surface roughness.

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Figure 9. Comparator Showing Relationship Between Cell Size and Cast Surface Roughness
Note: Data matrices in Figure 9 are not IUID compliant.

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Appendix F. Data Matrix Module Size by Environment

See Figure 10 for guidance regarding appropriate data matrix cell sizes to overcome damage
from different grades of environmental exposure.

Mild Environments Moderate Environments Harsh Environments

General office conditions Indoor or general outdoor use. Harsh indoor/outdoor
where there are moderate Parts are exposed to some conditions; long-term
temperatures and minor chemicals and abrasives,
exposure to salt air, caustics;
exposure to non-abrasive moderate cleaning and extreme temperature
cleaning chemicals. Examples exposure to outdoor variations; exposure to
include office furniture, environments in temperate chemicals, including
calculators, computers, regions. Examples are in-plant petroleum products; frequent
reproduction machines, and so fixed assets, embedded parts, cleaning and exposure to
forth. internal air, sea or ground autoclaves, chemicals, or
vehicle components (less
abrasives. Examples are
engines), and so forth. external aircraft components,
engine parts other than
internal combustion engine
components, refinery
equipment, work-in-process
manufacturing, and tools

Minimum suggested cell size Minimum suggested cell size Minimum suggested cell size
0.008-inch required for 0.010 inch (0.254 mm). 0.020 inch (0.508 mm) or
successful reading. larger.

Minor damage can render a Error correction can reconstruct Less error correction needed.
mark unreadable. symbol.

Figure 10. Minimum Cell Sizes for Expected Use Environments

Cell sizes must be adjusted upwards to overcome anticipated environmental damage without
exceeding the specification cell size limit of 0.025 inch. In general, operators should use the
largest cell size practical.

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Appendix G. Cell Size Limits & Techniques to

Overcome Size Limits
Cell Size Limits
MIL-STD-130 requires cell sizes to be no bigger than 0.025 inches and no smaller than 0.0075
inches unless specified by contract. Deviations outside these cell size limits are not
recommended since commercially available scanners are not designed to read them without
customized optics.
The upper limit of cell size can be further constrained by limits on the size of the overall data
matrix. MIL-STD-130 limits the longest dimension of the data matrix to no bigger than 1 inch.
Since 40 cells, each 0.025 inches to a side, would consume the entire 1 inch, any data matrix
having data requiring more than a 40-cell wide data matrix must use cells smaller than 0.025
inches. Because items may not have 1 inch to spare for a data matrix symbol, the maximum
number of cells to a side may need to be fewer than 40.
The data matrix specification 6 permits 30 different sizes for symbols, 6 of which are rectangular,
the remaining 24 are square. The largest and smallest sizes cannot be used for IUID due to IUID
size and/or data requirements 7 (indicated with bold, italic, underlined font in Table 2).
For large items (items that can accommodate a 1-inch mark), the amount of data encoded into the
mark is not usually an issue. However, for items with severely limited marking area, limiting the
encoded data or finding ways to compact the encoded data can be critical.
For example, assume an item is limited to using a 0.25 inch by 0.25 inch data matrix and exists
in a harsh environment that optimally would have a 0.20 inch cell size. The geometry dictates
use of a 10x10 data matrix for this area and cell size. A 10x10 data matrix does not have enough
data capacity for IUID. This item will need to be marked with cells less than the recommended
0.20 inch. Encoding a minimum amount of data will lead to larger cell sizes and a more robust
mark. In this case, the operator should compact the IUID data as much as possible. Note that a
reduction in the encoded data does not always lead to fewer modules. For example, there will be
no size benefits to the data matrix if a particular encoded string shrinks from a data capacity of
29 to 23. In either case, a 22x22 data matrix must be used.

6
ISO/IEC 16022
7
MIL-STD-130N, ISO-IEC 15434

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Rows Columns Max. Module Size Data Capacity

10 x 10 0.025” 3
12 x 12 0.025” 5
14 x 14 0.025” 8
16 x 16 0.025” 12
18 x 18 0.025” 18
20 x 20 0.025” 22
22 x 22 0.025” 30
24 x 24 0.025” 36
26 x 26 0.025” 44
32 x 32 0.025” 62
40 x 40 0.025” 86
Square Data
44 x 44 0.023” 114
Matrices
48 x 48 0.021” 174
52 x 52 0.019” 204
64 x 64 0.016” 280
72 x 72 0.014” 368
80 x 80 0.013” 456
88 x 88 0.011” 576
96 x 96 0.010” 696
104 x 104 0.010” 816
120 x 120 0.009” 1050
132 x 132 0.008” 1304
144 x 144 0.0069 1558
8 x 18 0.025” 5
8 x 32 0.025” 10

Rectangular Data 12 x 26 0.025” 16

Matrices 12 x 36 0.025” 22
16 x 36 0.025” 32
16 x 48 0.021” 49

Table 2. Data Matrix Cell Size and Capacity Chart

Encoded Data Compaction
The data matrix specification defines several encoding methods. Explaining these methods and
the capacity required for each with a given string of data is complex and beyond the scope of this
guide. It is made more complicated in that IUID compliant data matrix symbols encode syntax
specified within ISO15434. The following are the important ideas to consider when optimizing

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the compaction of any encoded data:

• Digits compact better than letters
• Digits compact when there are two of them together in the data (2 digits = 1 unit of
capacity; which is also known as a “code word” in the vernacular of the specification)
• Using “macros” to encode the ISO15434 syntax will reduce the required capacity by 7
units
o Macros are sometimes referred to as a “prefix” in barcode-generating software
o Macros are not supported by all marking devices but are supported by all readers
o “Macro05” is available when using Application Identifiers (GS1 data qualifiers)
o “Macro06” is available when using Data Identifiers (MH10.8.2 data qualifiers)
o A macro that can be used with Text Element Identifiers (ATA data qualifiers) is not
available.
• The exact same UII can be encoded in different ways to optimize cell size (see Figure 11
and Figure 12).

Figure 11. Minimizing Cell Count Through Optimized Encoding

Figure 12. Optimizing Cell Size Within a Fixed Area

(Enlarged to show comparison)

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Appendix H. Surface Preparation

Prior to applying additive markings the surface should be clean. The surface can be cleaned
using either compliance wipe-cleaning procedures or CO2 laser surface cleaning.
Compliance Wipe
The compliance wipe removes solid particulate contaminants (dust and dirt) and fluid films (oils)
that would compromise the attachment strength of the mark. A supply of clean, lint-free wipes
as well as a supply of an appropriate solvent is required to perform a compliance wipe. Use a
solvent to dissolve the surface contaminants, and then wipe off the surface with a clean, dry
wipe. If the solvent is permitted to dry on the item’s surface before it is wiped off, the
contaminants will precipitate back onto the surface, thus rendering the compliance wipe
ineffective. Take care to enforce use of authorized solvents—many household cleaning products
include “shine factors” that purposefully leave problematic residues that promote the appearance
of a clean surface. General purpose solvents like water and isopropyl alcohol are useful in many
but not all situations. For example, isopropyl alcohol is known to react with hydraulic fluid to
create a sticky acrylic resin. If this resin should be introduced into a hydraulic system it is
possible to cause a variety of problems.
Military cleaning technical instructions and procedures are defined in a many different technical
standards, handbooks, and guides written with reference to specific materials, products, and end-
item types. Use cold-cleaning processes for marking mechanical and structural parts. Cold
cleaning is done by immersing and soaking, spraying, or wiping the parts to be marked with
ambient temperature solvents.
Compliance wipe cleaning solvents used to remove contaminants are defined in MIL-PRF-
87937. The specification establishes requirements for biodegradable, water dilutable,
environmentally safe cleaning compounds for use on aerospace equipment such as aircraft,
aerospace ground equipment (AGE), and AGE engines.
Alternative cleaning materials are identified in MIL-C-38736. These solvents are obtainable
under the following commercial brand names: Exxon Corporation’s Isopar C, E, G, H, K, L, M,
V; Axarel 9100 (isoparaffins); and 3M™’s PF-5050, PF-5052, PF-5060, PF-5070, and PF-5080
(perfluorocarbons).
Operators should refer to applicable engineering drawings to obtain cleaning procedures for
electronic parts, delicate items, or parts that have been precision cleaned and have close
tolerances, complex geometries, and/or are sensitive to contamination.
CO2 Laser Surface Cleaning
CO2 laser surface cleaning is typically used to produce a bare metal surface quickly and
efficiently. Before compromising paint and corrosion-resistant coatings, consult the appropriate
technical authority. Laser-bonded markings can be applied only to clean bare metal. If the bare
metal surface to be marked cannot be cleaned using compliance wipe procedures (for example,
the surface is coated with difficult-to-remove carbonized soils, oxidation, or contaminated with
combustion residue), the surface can be cleaned with a low-power CO2 laser (<40 watts). This
can be done quickly without masking, chemicals, fear of damaging the metal, or adversely
affecting material properties. CO2 laser surface cleaning is accomplished by inputting a program
into the laser controlling software that defines a surface removal patch of the appropriate size

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and then running the program using low power. Multiple passes are made across the area until
the bare metal surface is reached. The cleared area should include an additional area around the
mark which is as wide as half the symbol’s width (longest side if a rectangle).

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Appendix I. Marking with a Label

MIL-STD-130N defines “label” as:
Label. An item marked with the identification information of another item and
affixed to that other item. A label may be of any similar or different material than
that of the item to which it is affixed. A label may be made of a metallic or non-
metallic material. Labels may be affixed to the identified item by any appropriate
means. Labels are often referred to as plates (i.e. data plate, name plate, ID plate,
etc.) however, label material and methods of marking and affixing have no
bearing on this distinction.
Before marking with a label, consider the following:
• How is the label attached to the item
• What material is used to make the label
• How is the data matrix mark applied to the label.
Method of Attachment
Labels are commonly attached with adhesives, adhesive tapes, structural epoxies, or rivets. Other
more exotic means are also possible.
Adhesives
The chemistry of adhesives is quite advanced and continues to become refined. Adhesives come
in three general categories: rubber-based adhesives, acrylic Pressure Sensitive Adhesives (PSA),
and silicone-based adhesives. Rubber-based adhesives degrade too easily to be used in IUID
marking. Most IUID-related uses should use acrylic-based PSAs. Silicone adhesives have niche
uses where high temperatures (~ 400°F) are found.
There are tens of thousands of specially formulated acrylic PSAs, because of the wide variety of
items marked with acrylic PSAs. Each formulation strives to find the optimum adhesive balance
between two specific properties (adhesion and cohesion) to make the strongest bond. When
adhesion fails, the adhesive separates from either the item’s surface or the label material. When
cohesion fails, the adhesive tears itself apart, leaving some adhesive stuck to the item and some
stuck to the label. In most adhesives, the attraction to other things (adhesion) is in opposition to
its attraction to itself (cohesion), so that as one gets stronger the other gets weaker. This is
manageable when applying labels to a fixed repetitive commodity, as found on manufacturing
production lines. However, this is not the case when performing legacy IUID marking.
Fortunately, there are some acrylic PSAs that have both high cohesion and high adhesive
strength and can be applied to diverse surface types.
Different types of surfaces vary in their “surface energy” (that is, stickiness). Higher surface
energy means greater stickiness. Lower surface energy means less stickiness. Non-stick
materials such as Teflon® have very low surface energy—around 18 dynes/cm2—whereas
polished copper might have a surface energy as high as 1,100 dynes/cm2 if it were very clean
(Table 3). The problem areas arise for IUID marking when trying to label plastics and powder
coated paints.

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Surface Energy Material

(dynes/cm2)
1103 Copper
840 Aluminum
753 Zinc
526 Tin
458 Lead
700 – 1100 Stainless Steel
250 – 500 Glass
50 ®
Kapton (Polymide)
47 Phenolic
46 Nylon
45 Alkyd Enamel
43 Polyester
43 Epoxy Paint
43 Polyurethane Paint
42 ABS
42 Polycarbonate
39 PVC (Polyvinyl Chloride)
38 ®
Noryl
38 Acrylic
38 ®
Polane Paint
37 PVA
36 Polystyrene
36 Acetal
33 EVA
31 Polyethylene
29 Polypropylene
28 ®
Tedlar
18 ®
Teflon

Table 3. Material Surface Energy

Adhesives are soft and never become truly hard. As such, they will sag if a constant force is
applied to them. Furthermore, adhesives only work within a range of temperatures and often
break down when exposed to UV radiation. In addition, adhesives are often susceptible to many
organic solvents. However, the large variety of adhesives continues to grow and, as it does, their
applicability expands.

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Adhesive Tapes
Adhesive tapes have adhesive on both the top and bottom of a carrier. They are useful if the
label does not come with pre-applied adhesive. The carrier can be made of differing sponge-like
material (foam tapes). These are useful in situations where surface roughness is high and are
also useful in absorbing shock and vibration.
Structural Epoxies
Like adhesives, a large variety exists and continues to grow. Epoxies have many of the same
features and drawbacks as adhesives, but differ in a couple of critical areas. Epoxies do not rely
completely on adhesion to maintain attachment. Furthermore, because epoxies become hard,
they can mechanically bond to a surface that has a certain amount of roughness. This also means
that epoxies can withstand constant forces. However, because they get hard, epoxies are
susceptible to stresses and strains from differential expansion and contraction due to different
materials having different coefficients of thermal expansion.
Rivets
When using rivets to attach labels, ensure that either all of the materials are the same (that is, the
label is made of the same material as the rivets, which are of the same material as the item to
which they are being attached), or make sure the label is electrically isolated from the item.
Label Material
Although labels can be made out of any suitable material, the most widely used label materials
are plastics (such as polyester) and metal foils due to their convenience and inexpensive
application. If the material is thin enough, marking can be accomplished with a thermal transfer
printer quickly, conveniently, and inexpensively. When used with a suitable adhesive, these thin
labels have wide application but are not durable enough for every application. Thicker label
stock improves durability, but increases the complexity of marking.
Application of the Data Matrix to the Label Material
Any direct part-marking method can be used to apply the data matrix mark to the label material.
High-contrast materials can be chemically or mechanically fused to the label as is the case with
thermal transfer printers, ink jet, laser printers, and laser bonding. Photosensitive or thermally
sensitive materials can be applied to the label over a large area (typically during manufacturing)
before the marking process selectively induces a color change in the applied material. This is
how direct thermal printing works as well as the array of laser markable products. Direct
chemical or laser etching of the label can also be used to form data matrix marks, creating
intrusive marks in the label material.
The following is a representative list of laser markable materials: 8
• Rubber labels
• Fabric labels
• Two-ply acrylic labels
• Stainless steel labels
• Aluminum labels.

8
The commercial availability of laser markable products continues to grow and specialize into niche applications.

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Appendix J. Marking Techniques Overview

Only a few marking techniques are suited to producing marks on demand in the field as is
required for many legacy part marking efforts. The following are some of these techniques.
Thermal Transfer Printing
The quality and durability of thermal transfer print depends on the label material and grade of
ribbon used. Hundreds of different materials are available. In applications where thermal
transfer labels are to be applied to parts, users should consider the use of a matte finish, white
polyester face stock top coated for thermal transfer printing, and coated with high-strength
permanent acrylic adhesive. The label material should be 2.0 mils (51 microns) thick or greater
and print should be applied using a polyester resin ribbon.
For maximum bond strength, the surface should be clean and dry. For best bonding conditions,
application surface and label stock should be within the manufacturer’s range of application
temperatures. Low temperature surfaces, normally below 50°F (10°C), can cause the adhesive to
become so firm that it will not develop maximum contact with the substrate. Excessively high
temperature surfaces can cause chemical breakdown of adhesives and material stock. Stronger
initial bonds can be achieved through increased rubdown pressure. Rubdown pressure is best
applied with a seam-roller.
Adhesives can be contaminated with skin oils unless specific precautions are used to prevent
this. The easiest method to avoid this type of contamination is to wear clean gloves when
applying the label. Alternatively, spatulas can be used to separate the label and adhesive from
the label’s liner to avoid direct contact with and contamination of the adhesive.
Stencils
Stencil markings are applied by depositing a marking agent onto a surface using a mask that has
openings corresponding to the shape of the desired marking. Marking stencils are generated
using photo-process technology, thermal printing, laser engraving, and mechanical micro-cutting
processes. Stencils can be created from a wide range of application-dependent materials
including, but not limited to, paper, vinyl, zinc, aluminum, polypropylene, and magnetic rubber.
Marking agents are applied to the part surface by spraying, rolling, or dabbing the agent through
the openings in the mask. The marking agents most commonly used with stencil marking are:
• Abrasive blast
• Acid etch
• Chemical coloring agents
• Dip, barrier, and chemical conversion coatings
• Paint
• Plating and electroplating
• Ink
• Thermal spray
• Vacuum and controlled atmosphere coatings, and surface modification processes.

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Laser and mechanically cut stencils need a symbol pattern that provides spacing between the data
cells to keep the pattern together. The spacing provides a grid of interconnecting data cell
elements that typically occupies approximately 36% of the individual data cell marking area
(Figure 13). Interconnecting data cell elements that occupy less than 26% of the allotted data
cell marking space can be damaged during stencil generation and handling, and those exceeding
46% of the allotted data cell area can adversely affect symbol readability.

Figure 13. Data Matrix Stencil

While all of the stencil generating methods described above can be made to work, the laser
engraving process is the quickest and produces the highest quality stencils. The stencil material
used to produce laser created stencils consists of a white 200 mesh polyester screen coated with a
colored thermoplastic polyester layer. This layer is removed to create the desired image without
the need for interconnecting elements as shown in Figure 13. To apply the marking to the part,
the surface is cleaned and the stencil taped down on the part surface. A drop of ink is then
applied to the side of the marking stencil and a squeegee or a plastic spreader is used to spread
the ink evenly across the opening in the stencil. One pass is usually sufficient. Some inks will
tend to dissolve the thermoplastic coating, so multiple passes should be kept to a minimum.
The application of IUID symbols using stencils, regardless of the stencil type used, can be
difficult because the operator must evenly press the media through hundreds of very small
openings in the stencil without smearing it across the unmarked data cell areas. This can be
challenging for even experienced technicians.

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Laser Coloring Technique

Laser coloring is a marking process that discolors (darkens) additives that are exposed to the
specific wavelength produced by the laser (Figure 14). These additives are contained in
commercially available paints, epoxy films, tags, and other media that can be added to parts. In
most cases, laser-colored markings are covered with a matte finish clear coat for environmental
protection. Some products have been shown to darken over time because of intermittent
exposure to heat and light.

Figure 14. Coating Applied to Substrate and Discolored with Laser

Laser Bonding Technique
Laser bonding involves a special paint applied to a part that is then marked to permanently fuse
components in the paint to the surface. The unmarked paint is then removed using a lint free
cloth saturated with water. (The end state of this process is represented in Figure 15.) Laser
bonding is possible for identifying legacy parts in the field that have been previously marked
with intrusive marking processes.

Figure 15. Material Fused to a Surface Using the Laser Bonding Process
Laser Engraving Technique
CO2 lasers can be used to strip away organic coatings to expose an underlying substrate. For
legacy applications, this can be done by:
• Removing the top coat of two-ply label or black anodized label
• Removing a coating of contrasting color applied over an existing coating
• Removing the original coating applied to the part during manufacturing.

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Markings made using this process expose the underlying material to corrosion, therefore
approval from the cognizant technical authority is required and approved procedures and
materials to apply when marking is complete are necessary. The corrosion preventive coatings
must be a clear matte finish or the mark will be ruined.

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Appendix K. Additive Marks

Additive markings are processes that mark by adding material to the item’s surface.
Additive markings can be accomplished by selectively applying material to the surface such as
direct ink-jet techniques, and various stencil and silkscreen methods. Additive marking can also
be accomplished by applying marking material over a wide area and selectively fusing the
material to the surface. The unfused material is then removed (usually by wiping the surface),
leaving the mark behind. Typically, material is selectively fused with a laser that melts the
marking material to the surface or by inducing chemical reactions that bind the marking material
to the surface. Additive marks can also be produced by applying specialized marking material
over a wide area that, after curing, is selectively discolored through a light-induced chemical
reaction. Again, this is usually accomplished with a laser. When using this last technique, take
care to ensure the chemical reaction is disabled after marking (fixed). Otherwise, heat and
various exposures to light will fade the mark as the rest of the material discolors.
Many additive marking processes designed to mark steel parts require all corrosion-resistant
coatings and paints to be removed. This should not be done without an approved procedure from
the technical authority for both the removal of existing coatings as well as the application of
replacement coatings. Unless the replacement coating is clear, it will very likely render the
additive mark useless.
Typical additive marking methods include:
• Direct ink-jet
• Laser bonding
• Laser markable paint
• Laser coloring
• Thermal spray
• Ink stencil
• Ink silkscreen
• Ink stamping.

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Appendix L. Common Part Marking Methods

There are two primary tools available to create IUID markings in the field for non-intrusive
application. These devices are: printers and laser markers to apply IUID markings directly to
the parts. Industry has other options for producing IUID markings in industrial facilities which
can be produced and shipped to sites for application.
Thermal Transfer Printing
A wide range of label printers are available on the commercial market. Thermal transfer printers
are preferred for IUID marking. These printers produce markings by using heat to transfer ink
from a ribbon to the label material. Selected printers should be capable of printing on 4-inch
label stock and be able to print one and two-dimensional bar codes. A print resolution of 300
dots per inch (dpi) or greater is preferred. The selected printers must be able to accept pre-
designed label templates and variable IUID information directly from both DON information
systems and/or commercially available middleware designed to produce barcodes and IUID
compliant symbols. Packaging labels formatting is specified in MIL-STD-129.
Laser Marking
Laser markers can be obtained commercially, configured for desktop or mobile applications
(carts). Laser systems can also be obtained that contain software designed to walk a novice
through marking technique selection options, provide instructions on how to mark, automatically
select the appropriate marking settings, and provide links to applicable reference standards and
safety documentation.
The CO2 laser (30-40 watts) is an excellent choice for field use because it will not damage metals
as is the case with shorter wavelength lasers. Shorter-wavelength lasers in this category include
Ruby-Neodymium doped: Yttrium Lithium Fluoride (Nd:YLF), Neodymium doped: Yttrium
Aluminum Garnet (Nd:YAG), Neodymiumdoped: Yttrium Aluminum Perovskite (Nd:YAP), and
Neodymium doped: Yttrium Vanadate Orthovanadate (Nd:YVO4). Visible wavelength lasers are
generally used to apply intrusive markings to metal substrates in controlled environments. CO2
lasers, with light in the infrared spectrum, are effective for marking organic materials such as
wood, leather, and certain plastics. Additionally, CO2 lasers can thermally fuse other materials
to metal to form IUID compliant markings.
Field site marking tests have demonstrated that a CO2 laser used in conjunction with appropriate
materials can safely apply IUID markings to parts typically found in a DoD depot or warehouse.

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Appendix M. Removal of Data Matrix Marks

Obliteration of Data Matrix Symbols
Many markings cannot be removed or otherwise corrected without deleterious effect to the
marked item. Consequently, they should be made unreadable by crossing the symbol out using
two diagonal lines that cross each other through the center of the data matrix; and two other lines
(one vertical, the other horizontal) through the two interrupted frame lines (finder pattern) of the
data matrix symbol (Figure 16).

Vertical and horizontal lines Diagonal lines crossing

through the interrupted through the center of
frame lines of the matrix the matrix
finder pattern

Figure 16. Obliteration of a Data Matrix Symbol

Original engineering drawings are written for a single marking for direct part markings. Since
repeated marking in the same area concentrates damage which has a cumulative effect on
material properties, original engineering marking authorizations should not be used to justify
additional marks. As such, personnel should refer unreadable direct part markings to quality
assurance for resolution. Quality assurance, working with engineering, should determine if the
marking is to be obliterated and the part remarked.
In instances where additive markings are coated with a clear coat for environmental protection,
the clear coat must be removed. Typically, if the clear coat has not fully cured (less than 24
hours since its application) the marking area is wiped with a clean lint-free cloth coated with a
Xylene-based solvent to remove the clear coat. If the coating has been on the surface for more
than 24 hours, a Methylene Chloride-based solvent is generally recommended. Both of these
solvents are considered to be potential occupational carcinogens and health hazards by the
Occupational Safety and Health Administration (OSHA). Therefore, users are advised to use a
safer substitute containing Aerostrip additive A FO606, approved by NAVAIR 01-1A-509, or
similar less hazardous solutions.
Laser Engraving
Markings made by removing painted surface coatings to form a mark can be repaired by painting
over the mark and reapplying the marking. Surface markings made by removing anodized
finishes are best corrected by removing the surface containing the marking using a laser and then
replacing it with a laser-bonded marking applied to the bare metal surface. The marked area
should then be coated with a clear coat for corrosion protection.
Laser Bonding
Laser-bonded markings can be removed using commercially available electronic weld cleaners,
which use alternating current and chemistry to clean the surface. The unit uses a wand, saturated
in a salt solution, to clean the surface using an instant electrochemical reaction. The combination
of electricity and chemistry generates heat, causing a deoxidizing reaction called “passivation.”
Using this process, laser-bonded markings can be removed in seconds.

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Labels
The least damaging method for removing labels applied with adhesive is the use of dry ice.
Applying dry ice to the label for 4-5 minutes causes the adhesive to become brittle. The label is
then tapped on the edge with a blunt object, preferably a plastic scraper, to free it from the item.
Any surface exposed after label removal should be restored to its original condition before the
new label is applied.
Ink and Paint
Ink and paint markings protected with a clear coat can be removed using a lint-free cloth
saturated with a solvent. In many cases this process will result in the part coating being
damaged. As such the appropriate Technical Authority should approve the solvent and processes
employed to remove the mark.

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Appendix N. Verification
Verification is necessary because of the error correction capability built into the data matrix.
This error correction allows all the data within a data matrix, even one with some damage, to be
quickly and consistently read with a scanner. Once the damage increases past a certain point
however, the data matrix will be completely unreadable. (Note: the error correction applies to
the data within the data matrix and not the quiet zone around the mark or the solid and broken
lines that form the edge of the mark.)
To ensure marks with the longest useful life are used, it is not sufficient to just scan them
because this gives no indication of how close the marks are to failing (i.e. how much of the error
correction is already used to decode the mark). Instead, verification is needed to evaluate how
close to failing the mark is. Standards and thresholds are specified within MIL-STD-130:
Data matrix symbol quality can be determined using any of the following standards: ISO/IEC
15415, AIM DPM-1-2006, or SAE AS9132
• ISO/IEC 15415 is designed to verify high contrast (black on white) marks and should be
used when evaluating such marks whenever possible.
• AIM DPM-1-2006 is designed to verify direct-part-marked items which typically have
low or no inherent contrast. These marks derive contrast from shadows, which are created
by illuminating irregular surface features with light at an angle. This standard should be
used to verify direct part marks made by forming irregular surface features whenever
possible.
• SAE AS9132 should be used if the above standards cannot be used.
From ISO/IEC 15415
The symbol shall have a minimum quality grade of 3.0/05/650 measured with an aperture size of
0.005 inch (0.127 mm) with a light source wavelength of 650 nm ± 20 nm. As an exception, the
ISO/IEC 15415 parameters Modulation (MOD), Symbol Contrast (SC), or both, may measure as
low as 2.0, providing the overall ISO/IEC 15415 grade would be 3.0 if the MOD and SC grades
are 3.0 or higher. (This allows for lower contrast substrates, high density images, printing, over-
laminates and other such limiting factors to the parameters MOD, SC, or both on otherwise well
produced images.) Quality (symbol validation and verification) reports shall clearly show that
the MOD, SC, or both, are the only parameters measured as low as 2.0, and clearly show that the
overall grade would be at least 3.0 if MOD and SC were at least 3.0. Quality reports shall also
document the synthetic aperture size used. The methodology for measuring the print quality shall
be as specified in ISO/IEC 15415, where the overall grade is based on a single scan (not five
scans).
From AIM DPM-1-2006
The symbol shall have a minimum quality grade of DPM2.0/7.5-
25/650/(45Q|30Q|90|30T|30S|D) where:
i. Minimum quality grade = 2.0
ii. X dimension range of the application = 7.5-25 mils
iii. Inspection wavelength = 650 nanometers ± 20 nanometers.

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iv. Lighting conditions = Medium Angle Four Direction (45Q) or Low Angle Four Direction
(30Q) or Diffuse Perpendicular (90) or Low Angle Two Direction (30T) or Low Angle
One Direction (30S) or Diffuse Off-axis (D).
Both validation and verification of machine readable information is required by MIL-STD-130.
In cases where labels are produced by a vendor and require verification and validation, a report
of conformance generated by verification and validation software can be used to document
compliance with the standard. If the labels are produced as a batch or lot where materials and
machine settings do not change and a sampling plan is employed, a set of reports of conformance
can be used to indicate compliance for the entire batch/lot, provided they include the size of the
batch/lot, define which labels fall within the population, and indicate which labels within the
population where verified. If labels are coated or covered by a protective substance after
manufacture, a sample should be verified to ensure that the coating or cover does not degrade the
quality of the mark below the standards cited in MIL-STD-130. If the marks may be subjected to
damage during operation, or cleaning, servicing, or repair processes, additional verification of
the marks may be necessary to ensure the marks remain useful through the item’s lifecycle or
next major overhaul.

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Appendix O. Quality Sampling Plans for Barcode Creation

To ensure the quality of the printed barcode is as high as possible, the mark should be verified.
Verifying ensures that the mark meets the standards for contrast, shape, cell size, reflectance, and
so forth. However, when large quantities of marks are needed, verifying every mark can be very
time consuming. MIL-STD-130 allows for the adoption of a lot acceptance sampling plan as a
method to test the integrity of a batch of barcodes without having to verify every barcode.
Lot acceptance sampling is an inspection procedure where a random sample is taken from a lot,
and upon the results of appraising the sample, the lot is either rejected or accepted as being of
acceptable quality.
The most common lot acceptance sampling procedure to use is to have a sampling plan and
decision rule. For the plan there are some parameters that are either chosen or determined and a
rule that tells us when to accept or reject a lot.

Sampling Plan:
N = lot size
n = sample size (randomized)
c = acceptance number
d = number of defective items in the
sample

Decision Rule:
If d ≤ c, accept the lot; else reject the lot,
in which case a 100% inspection must be
done.

Because each label is not being verified, there are certain risks involved in this procedure:
producer’s risks and consumer’s risks.

Producer’s Risk (α) is the probability of

rejecting a lot that is good.
Consumer’s Risk (β) is the probability of
accepting a lot that is bad.

For most sampling procedures, the producer’s risk is typically set at 5% and the consumer’s risk
is set at 10%.
The statistical properties of the acceptance sampling procedure can be determined by considering
how the acceptance probability depends on the true proportion d of defective items in the lot. It
is usual to define an Acceptable Quality Level (AQL), c say, so that a lot is considered
acceptable as long as d ≤ c. In this way the producer’s risk is the probability of rejecting lots that
are at an AQL. Another term often used is the Lot Tolerance Proportion Defective (LTPD).
This is the worst level of quality tolerable. The consumer’s risk then corresponds to the
probability of accepting lots at the LTPD.

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Table 4 provides the random sample of labels that need to be verified and the maximum number
of defects that are allowed in the sample, in order for the entire lot to be accepted for a given lot
size. For example, if 100 labels were printed, 54 of them would be randomly verified. If more
than 4 barcodes failed verification, the quality of the lot would be rejected and all 100 barcodes
would be verified, discarding those that failed verification.
Lot Size Sample Size Max. Defects
to Test to Accept Lot
1-25 21 1
26-50 41 3
51-100 54 4
101-150 75 6
151-200 78 6
201-300 89 7
301-500 101 8
501-600 112 9
601-800 113 9
801-1000 114 9
1000-5000 125 10

Table 4. Sampling Plan Examples

Since the printing of barcodes is a mechanical process, one would expect print quality to begin
deteriorating towards the end of a lot. To ensure this fact is taken into account, it is best to divide
the number of barcodes you are printing into three batches and randomly verify 20% of the
samples in the first third, 30% in the second third, and 50% in the last third, always choosing the
last barcode in the lot as one of the samples.
References
R Development Core Team (2008). R: A Language and Environment for Statistical Computing. R Foundation for
Statistical Computing, Vienna, Austria, ISBN 3-900051-07-0, URL http://www.R-project.org/
Schilling EG (1982) Acceptance Sampling in Quality Control, Marcel Dekker, Inc.
Kiermeier, A., Visualizing and Assessing Acceptance Sampling Plans: The R Package Acceptance Sampling,
Journal of Statistical Software, July 2008, Volume 26, Issue 6.

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Appendix P. Useful Process Control Techniques

These techniques do not constitute a print quality check of the produced symbols required per
MIL-STD-130 but nonetheless yield good indications of whether the symbol print process is
creating workable symbols.
Special Reference Symbol
For process control purposes, a 16x16 ECC 200 reference symbol can be printed that encodes the
data “30Q324343430794<OQQ.” As shown in Figure 17, this reference symbol has a region of
parallel bars and spaces. Printing the reference symbol in different orientations allows different
print alignment flaws to be seen with proper magnification. A 30x jeweler’s loupe is useful for
this purpose. This symbol is particularly useful if a linear barcode verifier is available as the
parallel lines in the upper left can be measured for contrast and print growth. ANSI X3.182 is
useful for this purpose.

Figure 17. ECC Reference Symbol (Not IUID Compliant)

Assessing Axial Nonuniformity
For any symbol, measure the length of both legs of the “L” shaped finder pattern. Divide each
length by the number of modules in that dimension, for example, a 12x36 symbol would have 12
and 36 as divisors. These two normalized dimensions are XAVG and YAVG, which can be used in
Equation 1 to grade axial nonuniformity. Table 5 associates axial nonuniformity values to the
letter grades used in the verification process.

Equation 1. Axial Nonuniformity

A (4.0) If AN ≤ 0.06
B (3.0) If AN ≤ 0.08
C (2.0) If AN ≤ 0.10
D (1.0) If AN ≤ 0.12
F (0.0) If AN > 0.12
Table 5. Axial Nonuniformity Grading Rubric

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Visual Inspection for Symbol Distortion and Defects

Ongoing visual inspection of the perimeter patterns in sample symbols can monitor two
important aspects of the print process.
First, data matrix symbols are susceptible to errors caused by local distortions of the matrix grid.
Any such distortions will show up visually in a data matrix symbol as either crooked edges on
the “L” shaped finder pattern or uneven spacings within the alternating patterns found along the
other two margins of the symbol. Larger ECC 200 symbols also include alignment patterns
whose straightness and evenness can be checked visually. Symbols likely to fail the reference
decode can be quickly identified this way.
Second, the two arms of the finder pattern and the adjacent quiet zones should always be solidly
in opposite reflectance states. Failures in the print mechanism that may produce defects in the
form of light or dark streaks through the symbol should be visibly evident where they infringe
the finder of quiet zone. Such systematic failures in the print process should be corrected.

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Appendix Q: Acronyms
A&LM Acquisition and Logistics Management

ADC Automatic Data Capture

AGE Aerospace Ground Equipment

AI/DC Automatic Identification and Data Capture

AIM Automatic Identification Manufacturers

ANSI The American National Standards Institute.

ASME American Society of Mechanical Engineers

ATA Air Transport Association

CO2 Carbon Dioxide

DASN Deputy Assistant Secretary of the Navy

DFARS Defense Federal Acquisition Regulations Supplement

DoD Department of Defense

DON Department of the Navy

DPM Direct Part Marking

EAN European Article Number

ECC Error Correction Code (equivalently Error Checking and Correcting)

ECM Electrochemical Machining

EDM Electro Discharge Machining

EEE Electrical, Electronic, and Electromechanical

ELM Expeditionary Programs and Logistics Management

ESD Electro Static Discharge

EN European Standard

FACT Federation of Automatic Coding Technologies

HDBK Handbook

IEC International Electrotechnical Commission

ISO International Organization for Standardization

IUID Item Unique Identification

Laser Light Amplification by Stimulated Emission of Radiation

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MOD Modulation

NASA National Aeronautics and Space Administration

NAVAIR Naval Aviation

nm Nanometer (0.000000001 meters)

P/N Part Number

QCTS Quick Compliance Tool Suite

OSHA Occupational Safety & Health Administration

RDA Research, Development and Acquisition

RMS Roughness Measurement Scale

SAE Society of Automotive Engineers

SEM Scanning Electron Microscope

SIM Serialized Item Management

S/N Serial Number

UCC Uniform Code Council

UID Unique Identification

UV Ultra Violet

VOCs Volatile Organic Compounds

WD Working Draft

YAG Yttrium Aluminum Garnet

YAP Yttrium Aluminum Perovskite

YLF Yttrium Lithium Fluoride

YVO4 Yttrium Vandate Orthovandate

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