Laser Plastic Welding 101

The latest evolution in joining technology

Before you go on!
Find out how to get a copy of LPKF’s Design Guidelines
document at the end of this presentation
Great for designer and
engineers in the design or
concept phases of
development

Design_Guidelines.pdf
Topics
1. What is Laser Plastic Welding?
• Basic Process

2. Applications and Industries

3. Advantages of Laser Plastic Welding

 Infrared
808 or 980nm
The Basic Process

1. Transmissive upper layer

2. Absorbing lower layer

3. Contact

4. Material compatibility

Laser passes through upper

transmissive layer
 Infrared
808 or 980nm
The Basic Process

1. Transmissive upper layer

2. Absorbing lower layer

3. Contact

4. Material compatibility

Laser is absorbed at surface

of lower layer, absorbed
energy creates heat
The Basic Process

1. Transmissive upper layer

2. Absorbing lower layer

3. Contact/Clamping

4. Material compatibility

Heat from lower layer is transferred to

upper layer through conduction
The Basic Process

1. Transmissive upper layer

2. Absorbing lower layer

3. Contact

4. Material compatibility
Materials must have similar properties,
especially similar melting temperatures
3 Main Industries
Automotive

Sensor – opaque cover layer CV Boot – soft to hard weld Sensor – hermetic seal
3 Main Industries
Medical

Microfluidic device – 2 meter Micro-atomizer – ultra small Ostomy bag – hidden joint
long joint line within size for hygiene regulations
3 Main Industries
Consumer Goods

MINI Car Key – compact, Shaver faceplate – aesthetically

durable, sensitive electronics pleasing weld seam
inside
Advantage: Lower Joining Costs
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: Lower Joining Costs

• No consumables
• Minimal maintenance
• Fewer failed parts

Consumer Elec. Medical Devices Automotive

Advantage: Minimal Part Stress
1. Lower Joining Costs
2. Minimal Part Stress
3. Joint Strength
4. 3D & Complex Shapes
5. No Particulate Development
6. Precision
7. Aesthetically Pleasing Welds
8. Weld Different Materials
9. Process Monitoring
Advantage: Minimal Part Stress

• Localized Heat
• (Small HAZ)
• Sensitive Applications
Advantage: Joint Strength
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: Joint Strength

• Pull or Burst Tests

• Weld > Parent Material

Consumer Elec. Medical Devices Automotive

Advantage: 3D & Complex Shapes
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: 3D & Complex Shapes

• TwinWeld 3D system
allows laser source to
move relative to joint

Consumer Elec. Medical Devices Automotive

Advantage: Hybrid Welding
Halogen Sources

• Halogen lamps assist in heating

• Faster cycle times
• No need for annealing process

Consumer Elec. Medical Devices Automotive

Advantage: No Particulates
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: No Particulates

• Particulate contamination
• No frictional motion

Consumer Elec. Medical Devices Automotive

Advantage: No Particulates

Laser Weld v. Friction Weld

Consumer Elec. Medical Devices Automotive

Advantage: Precision
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: Aesthetically Pleasing
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: Weld Different Materials
1. Lower Joining Costs
2. Minimal Part Stress
3. 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

Advantage: Weld Different Materials

• Hard-to-Soft Welds

Consumer Elec. Medical Devices Automotive

Advantage: Weld Different Materials

• Soft-to-Soft Welds

Consumer Elec. Medical Devices Automotive

Advantage: Process Monitoring
1. Lower Joining Costs
•2. Melt
Minimaltravel monitoring
Part Stress
3. Joint Strength
• Pyrometer Path
4. 3D & Complex Shapes
•5. Reflection
No Particulatediagnosis
Development
6. Precision
•7. Burn detection
Aesthetically Pleasing Welds Time

8. Weld Different Materials Multiple process monitoring techniques

ensure quality and fewer failed parts
9. Process Monitoring
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

Thank you!
Would you like more information?
Request a copy of our Design Guidelines
document by contacting Josh Brown
• jbrown@lpkfusa.com
• 503-454-4231

Design_Guidelines.pdf