Data matrix symbols are used as a robust means of unique part identification in many industries. Research of cast data matrix symbols has been limited and expected symbol performance unknown. To develop knowledge of cast data matrix symbol performance, the investigation initially focused on feasibility of casting data matrix symbol. Results of a feasibility experiment led to further investigation of cast symbol design expected performance.

Bump marks were evaluated initially due to the inherent ease of production and use in previous cast data matrix applications. The results indicate Bump mark geometry is problematic, due to the inherent nature of shadow formation as a means to create contrast marks. Using design inspiration from Dot Peen data matrix symbols, an alternative cast data matrix design was pursued and analyzed. The results of this modified Dimple mark geometry proved to be superior to the Bump contrast symbol geometry in side by side analysis. A deeper analysis at the module level was also pursued to determine the effect on Print Growth and Symbol Contrast for an array of mark diameters, spacing and surface roughness values. Also, an optimal light angle was selected based on the ANOVA analysis and Print Growth_m and Symbol Contrast averages.

An applicable design was presented with the use of a heuristic to select ideal symbol factors, which indicated the physical size for aluminum cast data matrix symbols with ten and 50 character capacities were determined to be 1.75 and 3.00 inches, respectively. Using the same methodology for ferrous cast data matrix symbols with ten and 50 character capacities, the physical symbol size was determined to be 2.19 and 3.75 inches, respectively.