Laser Plastic Welding 101 -...
Transcript of Laser Plastic Welding 101 -...
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Laser Plastic Welding 101 The latest evolution in joining technology
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Josh Brown Marketing Development
Representative
Follow us @LPKF_USA
Watch the video recording here
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Contact
or
http://www.laserplasticwelding.com/de
sign-guidelines-full LPW_Design_Guidelines.pdf
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1. What is laser plastic welding?
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2. Why should I care about it?
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3. Is it right for my application?
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1. Transmissive upper layer
2. Absorbing lower layer
3. Contact
4. Material compatibility
Infrared
808 or 980nm The Basic Process
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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
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1. Transmissive upper layer
2. Absorbing lower layer
3. Contact
4. Material compatibility
Infrared
808 or 980nm The Basic Process
![Page 11: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/11.jpg)
1. Transmissive upper layer
2. Absorbing lower layer
3. Contact/Clamping
4. Material compatibility
The Basic Process
![Page 12: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/12.jpg)
1. Transmissive upper layer
2. Absorbing lower layer
3. Contact
4. Material compatibility
The Basic Process
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2. Advantages
Adhesives
Hot Plate
Friction Laser
Extrusion
Ultrasonic
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….picks up where other methods leave off
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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
Automotive Medical Devices Consumer Elec.
![Page 16: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/16.jpg)
Automotive Medical Devices Consumer Elec.
• No consumables
• Minimal maintenance
• Fewer failed parts
Lower Joining Costs
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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
![Page 18: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/18.jpg)
• Localized Heat
• Small HAZ
• Sensitive Applications
Minimal Part Stress
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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
Hermetical Seal & Joint Strength
Automotive Medical Devices Consumer Elec.
![Page 21: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/21.jpg)
• Pull or Burst Tests
• Weld > Parent Material
Automotive Medical Devices Consumer Elec.
Hermetical Seal & Joint Strength
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Automotive Medical Devices Consumer Elec.
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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
Automotive Medical Devices Consumer Elec.
3D & Complex Shapes
![Page 24: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/24.jpg)
• Laser source moves
relative to joint
3D & Complex Shapes
Automotive Medical Devices Consumer Elec.
![Page 25: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/25.jpg)
Hybrid Welding
Automotive Medical Devices Consumer Elec.
Halogen Sources
• Halogen lamps assist in heating
• Volumetric heating
• Faster cycle times
• No need for annealing process
![Page 26: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/26.jpg)
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
No Particulates
Automotive Medical Devices Consumer Elec.
![Page 27: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/27.jpg)
• Particulate contamination
• No frictional motion
Automotive Medical Devices Consumer Elec.
No Particulates
![Page 28: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/28.jpg)
Automotive Medical Devices Consumer Elec.
Laser Weld v. Friction Weld
No Particulates
![Page 29: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/29.jpg)
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
Precision
Automotive Medical Devices Consumer Elec.
![Page 30: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/30.jpg)
Automotive Medical Devices Consumer Elec.
Precision
![Page 31: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/31.jpg)
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
Aesthetically Pleasing
Automotive Medical Devices Consumer Elec.
![Page 32: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/32.jpg)
Automotive Medical Devices Consumer Elec.
Aesthetically Pleasing
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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
Automotive Medical Devices Consumer Elec. Medical Devices Automotive
Weld Different Materials
![Page 34: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/34.jpg)
Weld Different Materials
• Hard-to-Soft Welds
Automotive Medical Devices Consumer Elec.
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Automotive Medical Devices Consumer Elec. Medical Devices Automotive
• Soft-to-Soft Welds
Weld Different Materials
![Page 36: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/36.jpg)
• Melt travel monitoring
• Pyrometer
• Reflection diagnosis
• Burn detection
Process Monitoring
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
Time
Path
Joint Example
![Page 37: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/37.jpg)
• Melt travel monitoring
• Pyrometer
• Reflection diagnosis
• Burn detection Time
Path
Joint Example
Process Monitoring
![Page 38: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/38.jpg)
• Melt travel monitoring
• Pyrometer
• Reflection diagnosis
• Burn detection
Process Monitoring
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• Melt travel monitoring
• Pyrometer
• Reflection diagnosis
• Burn detection
Process Monitoring
![Page 40: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/40.jpg)
• Melt travel monitoring
• Pyrometer
• Reflection diagnosis
• Burn detection
Process Monitoring
![Page 41: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/41.jpg)
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
![Page 42: Laser Plastic Welding 101 - lpkfusa.comlpkfusa.com/webinars/slides/laser-plastic-welding-101-webinar.pdf · Contact jbrown@lpkfusa.com or LPW_Design_Guidelines.pdf sign-guidelines-full](https://reader034.fdocuments.us/reader034/viewer/2022051407/5acf70c27f8b9a1d328d0189/html5/thumbnails/42.jpg)
More Resources…
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Material Compatibility Chart
Q&A
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Joint Design: Radial
Q&A
Fixed laser / moving part Fixed part / moving laser
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Joint Design: Lap (common)
Post-collapse Pre-collapse
Q&A Process
Mntr
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Clamp Tooling
Q&A
Transparent, acrylic Hybrid: metal/acrylic All metal, dual
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Laser Staking
Q&A
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Material Thickness & Transmission
Q&A Q&A Reg. Q&A
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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
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20 Tire Guard 2 3 Sensor Cluster 12 Side impact
Satellites
19 Gear Sensor 14 Airbag Control
Unit
18 Gear Sensor
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Application Examples
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Air valve Oil level sensor Gear sensor
Key Pressure sensor Gear sensor
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More Application Examples
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No-Gluing Fluidics Electronics Mechatronics
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Heating
mechanism
Radiation Friction
Infrared
Laser Spin
Vibration
High frequency
Ultrasonic
External friction Internal friction Hot gas
Conduction
Hot plate
Convection
Extrusion
Glueing Hot melting Screwing Snap fit