Laser plastic welding is a proven and efficient method for joining plastics. This technology has been serving the industry for over two decades, boasting unmatched capabilities such as precise welding joints, minimal flash, no particulate, and the ability to handle a wide range of part sizes.
The process primarily employs an infrared (IR) laser which penetrates an IR-transmissive layer of plastic to be absorbed by an underlying IR-absorptive layer. This technique is known as through-transmission welding.
There are several types of laser welding that apply energy differently. Simultaneous laser welding utilizes fiber optics to distribute laser energy along the entire weld joint concurrently. Quasi-simultaneous welding quickly moves a single laser beam along the weld joint with multiple passes to mimic the effect of simultaneous welding.
Line beam or curtain welding uses optics to spread the laser energy into a curtain passed over the part, similar to using a broad paintbrush. Masking, on the other hand, employs a precisely cut mask to shield areas that do not require laser energy
The choice of laser welding method depends on a variety of parameters such as the complexity and size of part geometry, material types, strength requirements, aesthetic needs, and assembly function. Our team can guide you through the advantages and disadvantages of each method and help select the most suitable one for your application.
Three key factors that help identify laser welding applications are precision and accuracy, flash control, and part size.
The powerful and focused energy of a laser allows for that energy to be precisely placed where it is needed; directly to the area that needs to be joined. Distributing radiant energy can be tricky but using a laser, the correct optics, and a galvanometer scanner, Extol’s laser welding system can deliver energy exactly where you want it, and keep it away from where you don't.
Welding plastic produces flash in all welding technologies. It’s a matter of what type of flash, how much, and how its managed. With laser plastic welding, the amount of flash can be very accurately controlled due to the precision of the energy distribution. Laser welding can also eliminate nasty particulate for a nice clean weld.
Laser plastic welding is effective for a wide variety of parts ranging from tail lamps to key FOBs. It can be especially useful for smaller parts where other welding technologies lack the cleanliness and precision needed. In these miniature applications, weld cycle times can be sub-five seconds while still producing a precise, strong weld.
While not as widely used as other joining technologies, laser welding is a proven, effective technology and a compelling way to join plastics. Think you have an application that could benefit from the power of laser welding? Get in touch with us using the contact form below to discuss your project!
Discover how Extol tailors their laser welding solutions to meet the needs of your application.