Laser Plastic Welding 101 The latest evolution in joining technology

Josh Brown Marketing Development Representative Follow us @LPKF_USA Watch the video recording here

Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf http://www.laserplasticwelding.com/de sign-guidelines-full

1. What is laser plastic welding?

2. Why should I care about it?

3. Is it right for my application?

The Basic Process Infrared 808 or 980nm 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility

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

The Basic Process Infrared 808 or 980nm 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility

The Basic Process 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact/Clamping 4. Material compatibility

The Basic Process 1. Transmissive upper layer 2. Absorbing lower layer 3. Contact 4. Material compatibility

2. Advantages Ultrasonic Adhesives Extrusion Hot Plate Laser Friction

.picks up where other methods leave off

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

Lower Joining Costs No consumables Minimal maintenance Fewer failed parts Consumer Elec. Medical Devices Automotive

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

Minimal Part Stress Localized Heat Small HAZ Sensitive Applications

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

Hermetical Seal & Joint Strength Pull or Burst Tests Weld > Parent Material Consumer Elec. Medical Devices Automotive

Consumer Elec. Medical Devices Automotive

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

3D & Complex Shapes Laser source moves relative to joint Consumer Elec. Medical Devices Automotive

Hybrid Welding Halogen Sources Halogen lamps assist in heating Volumetric heating Faster cycle times No need for annealing process Consumer Elec. Medical Devices Automotive

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

No Particulates Particulate contamination No frictional motion Consumer Elec. Medical Devices Automotive

No Particulates Laser Weld v. Friction Weld Consumer Elec. Medical Devices Automotive

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

Precision Consumer Elec. Medical Devices Automotive

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

Aesthetically Pleasing Consumer Elec. Medical Devices Automotive

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

Weld Different Materials Hard-to-Soft Welds Consumer Elec. Medical Devices Automotive

Weld Different Materials Soft-to-Soft Welds Consumer Elec. Medical Devices Automotive

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

Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Path Burn detection Time Joint Example

Process Monitoring Melt travel monitoring Pyrometer Reflection diagnosis Burn detection

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

More Resources

Material Compatibility Chart Q&A

Joint Design: Radial Fixed part / moving laser Fixed laser / moving part Q&A

Joint Design: Lap (common) Pre-collapse Post-collapse Q&A Process Mntr

Clamp Tooling Transparent, acrylic Hybrid: metal/acrylic All metal, dual Q&A

Laser Staking Q&A

Material Thickness & Transmission Q&A Reg. Q&A

System Metric (focus diameter) English LQ-Vario 210 x 210mm 8 x 8 110 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 1.8 110 x 110 mm 4.3 x 4.3 154x 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

Q&A Reg. Q&A

20 312 19 14 18 Sensor Side Tire Airbag Gear Guard impact Sensor Cluster Control Satellites Unit Q&A Reg. Q&A

Application Examples Oil level sensor Air valve Gear sensor Gear sensor Key Pressure sensor Q&A Reg. Q&A

More Application Examples Electronics Fluidics Mechatronics No-Gluing Q&A Reg. Q&A

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