Laser Plastic Welding 101 The latest evolution in joining technology
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1 Laser Plastic Welding 101 The latest evolution in joining technology
2 Josh Brown Marketing Development Representative Follow Watch the video recording here
3 Contact or LPW_Design_Guidelines.pdf sign-guidelines-full
4 1. What is laser plastic welding?
5 2. Why should I care about it?
6 3. Is it right for my application?
7
8 The Basic Process Infrared 808 or 980nm 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility
9 The Basic Process Does not have to be optically transparent, just laser transparent 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility
10 The Basic Process Infrared 808 or 980nm 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility
11 The Basic Process 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact/Clamping 4. Material compatibility
12 The Basic Process 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility
13 2. Advantages Ultrasonic Adhesives Extrusion Hot Plate Laser Friction
14 .picks up where other methods leave off
15 Lower Joining Costs 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
16 Lower Joining Costs No consumables Minimal maintenance Fewer failed parts Consumer Elec. Medical Devices Automotive
17 Minimal Part Stress 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring
18 Minimal Part Stress Localized Heat Small HAZ Sensitive Applications
19
20 Hermetical Seal & Joint Strength 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
21 Hermetical Seal & Joint Strength Pull or Burst Tests Weld > Parent Material Consumer Elec. Medical Devices Automotive
22 Consumer Elec. Medical Devices Automotive
23 3D & Complex Shapes 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
24 3D & Complex Shapes Laser source moves relative to joint Consumer Elec. Medical Devices Automotive
25 Hybrid Welding Halogen Sources Halogen lamps assist in heating Volumetric heating Faster cycle times No need for annealing process Consumer Elec. Medical Devices Automotive
26 No Particulates 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
27 No Particulates Particulate contamination No frictional motion Consumer Elec. Medical Devices Automotive
28 No Particulates Laser Weld v. Friction Weld Consumer Elec. Medical Devices Automotive
29 Precision 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
30 Precision Consumer Elec. Medical Devices Automotive
31 Aesthetically Pleasing 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
32 Aesthetically Pleasing Consumer Elec. Medical Devices Automotive
33 Weld Different Materials 1. Lower Joining Costs 2. Minimal Part Stress 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes 5. No Particulate Development 6. Precision 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Consumer Elec. Medical Devices Automotive
34 Weld Different Materials Hard-to-Soft Welds Consumer Elec. Medical Devices Automotive
35 Weld Different Materials Soft-to-Soft Welds Consumer Elec. Medical Devices Automotive
36 Process Monitoring 1. Lower Joining Costs Melt travel monitoring 2. Minimal Part Stress Pyrometer 3. Hermetic Seal & Joint Strength 4. 3D & Complex Shapes Reflection diagnosis 5. No Particulate Development 6. Precision Burn detection 7. Aesthetically Pleasing Welds 8. Weld Different Materials 9. Process Monitoring Path Time Joint Example
37 Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Path Burn detection Time Joint Example
38 Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Burn detection
39 Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Burn detection
40 Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Burn detection
41 3. Disadvantages 1. Initial capital investment 2. Part geometry limitations Transmissive layer max thickness of 3mm 3. Plastics must be optically suited 4. Tight part tolerances Precise part molding needed no warpage or gaps
42 More Resources
43 Material Compatibility Chart Q&A
44 Joint Design: Radial Fixed part / moving laser Fixed laser / moving part Q&A
45 Joint Design: Lap (common) Pre-collapse Post-collapse Q&A Process Mntr
46 Clamp Tooling Transparent, acrylic Hybrid: metal/acrylic All metal, dual Q&A
47 Laser Staking Q&A
48 Material Thickness & Transmission Q&A Reg. Q&A
49 System Metric (focus diameter) English LQ-Vario 210 x 210mm 8 x x 110 mm 4 x 4 LQ-Power 45 x 45mm (.6mm) 1.8 x 1.8 (23.6 mils) 110 x 110 mm (1.2mm) 4.3 x 4.3 at (47.2 mils) 154 x 154mm (1.3mm) 6.1 x 6.1 at (51.2 mils) LQ-Integration 45 x 45 mm 1.8 x x 110 mm 4.3 x x 154 mm 6.1 x 6.1 TwinWeld 3D 600 x 600mm 23 x 23 1,200 x 1,200mm 47 x 47 Q&A Reg. Q&A
50 Q&A Reg. Q&A
51 Q&A Reg. Q&A
52 Q&A Reg. Q&A
53 Sensor Side Tire Airbag Gear Guard impact Sensor Cluster Control Satellites Unit Q&A Reg. Q&A
54 Application Examples Oil level sensor Air valve Gear sensor Gear sensor Key Pressure sensor Q&A Reg. Q&A
55 More Application Examples Electronics Fluidics Mechatronics No-Gluing Q&A Reg. Q&A
56 Heating mechanism Conduction Convection Friction Radiation Hot plate Hot gas Internal friction External friction Infrared Extrusion High frequency Spin Laser Ultrasonic Vibration Glueing Hot melting Screwing Snap fit Q&A Reg. Q&A
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