Plastic Welding

with Diode Lasers

June 2005

Laserline GmbH ! Muelheim-Kaerlich ! Germany

www.laserline.de

Laserline GmbH, Germany 1

Characteristics of Diode Laser
Advantages of Diode Lasers

1-step quick-welding

Flexible, any desired welding contour

Non-contact, fluff-free

Easily automated, high process stability

Low thermal and mechanical stress

Top-Hat-beam profile w/o intensity peaks

Applications

Gas-/fluid proof containers, electronic-

/sensor-housings, automotive parts, etc.
Direct diode laser on robot in production. Photo: Toyota

Laserline GmbH, Germany 2

Plastic Welding with Diode Lasers

Joining of Plastics with Diode Laser

" An Industrially Proven Process !

Content
Basics
Types of Welding Processes
Joining Techniques
Examples
Outlook

Laserline GmbH, Germany 3

Welding of Plastic: Principle

Laser Beam Transmits Top Shell

Laser Beam

F
Absorption in the Welding Zone
Bottom Shell
translucent
Movement
Direction
Melting of Both Parts by Heat Convection

Weld-Seam Invisible Weld-Seam

absorptive No Damage to the Surface

Laserline GmbH, Germany 4

Welding of Plastic: Basics
Polymers for Plastic Welding

Thermoplastics (Amorphous or Partially

Crystalline) but not Duroplastics or Elastomeres

Overlapping Melting-Temperature

Comparable Melt Behaviour (Polarity etc.)

Transmission / Absorption Characteristics for

Laser Wavelength: One Transparent, One
Absorbing Layer
Mechanisms of Connection

Intermolecular Forces Between Molecule Chains

Mechanical Attachment by Macro-Molecules That

Diffuse from one Part to the Other

Laserline GmbH, Germany 5

Main Parameters
Parameters " Welding System
Laser: beam forming, wavelength, optical power,
spot size, energy distribution
Machine concept: laser, manipulating system
Weld Results
(positioning), cooling unit, electrics, other external
components Width of the seam
(HAZ)
Parameters " Parts
Optical results
Combination of thermoplastics (thermal, mechanical
and optical properties " additives!) Resulting strength

Type and positioning of weld seam, thickness, parts Internal strains

design

Parameters " Process

Welding speed, cycle time, absorption of heat /
reaction time

Laserline GmbH, Germany 6

Welding of Plastic: Basics

Source: VDI Kunststofftechnik/BASF

Laserline GmbH, Germany 7

Welding of Plastic: Basics

Source: VDI Kunststofftechnik/BASF

Laserline GmbH, Germany 8

Welding of Plastic: Basics
Laser
F
Weld Joint Transmission welding
translucent

Quality of weld depends on:

absorptive
F

Welding pressure

Flatness of parts-surface

Thickness of transparent welding

partner

Laserline GmbH, Germany 9

Welding of Plastic: Basics

Typical Part Design with Process Control by Welding Path

Laser
F

Visible Notch
Setting Path

Laserline GmbH, Germany 10

 Plastic Welding: Typical Data
1000

te n
Laser
Hr
DioScan, Direct, Fiber-Coupled and
Beam quality [mm mrad]

en
ic e i
la sstch g
o ff
w
H a rtl
te n ssc hw e
i e n
Multi-Diode Lasers
100
Pnst ldin
s t Au ftra g

We
Ku en
S chwei
eien
L
te n
Hybrid
schw
n
Power
we i e
f sch
iden T ie
Schne
10 50 W to 800 W
10 100 1000 10000
Power [W]
Beam quality

< 150 mm mrad

Spot dimensions

0.5 to 5 mm

Material
- Thermoplaste
Electronics housings
- Thermoplastische Elastomere (TPE)
Laserline GmbH, Germany 11
Diode Laser Types for Plastic Welding

Direct diode laser, LDL 40

Multi diode laser system (100 diode laser sources)

DioScan F Fiber-coupled diode laser LDM

Laserline GmbH, Germany 12

Plastic Welding: Options
DioScan: beam scanner with PC or stand-alone control,
scanner software and integration for plastic welding
Optics with different beam dimensions and working distances
1-inch or 2-inch optics
Ring focus optics for simultaneous welding of circular seams
Circumferential weld optics for welding of tubes
Pyrometer and CCD camera for process monitoring

Laserline GmbH, Germany 13

Variants of Welding Processes

I. Quasi-Simultaneous Welding (QS):

Uniform, step-by-step heating of the

weld zone
Rotation symmetric parts or any
desired 2D-contour

II. Contour Welding:

One-step-welding process
Any desired geometry, 3D contour

Laserline GmbH, Germany 14

Special Variants I

Multi-Laser-System:

Rotation symmetric parts

Uniform, simultaneous heating of

different weld zones

Shortest cycle time

Cost reduction due to less process

stations

Laserline GmbH, Germany 15

Special Variants II

Simultaneous Welding:

Uniform, simultaneous Heating of

the Weld Zone

No internal strains, any part

geometry

Reduced cycle time

Low flexibility, high complexity

Laserline GmbH, Germany 16

Special Variants III
Scheme: Special Optics
Laser-light-cable

Laser beam

Collimating optics

Circular focusing optics

Special focusing optics for circular focus geometry

AXICON
Parabolic mirror

Rotation symmetric part

Laserline GmbH, Germany 17

Systems Advantages

Weld Geometry \ Laser Direct & Fiber-Coupled Scan-System Multi Diode

(QS) (simultaneous)

Spot Welds

Contour Welds

Multi-Spot Welds

Step Welds

Laserline GmbH, Germany 18

I. System Concept: Multi-Laser

Multi-Laser-System

Redundant system

Shortest cycle time

100-Laser-System

Applications

Structures

Foils

Rotation symmetrical parts

Twin-Laser-System

Laserline GmbH, Germany 19

II. System Concept: QS-Welding

DioScan

Simple manipulation system Laser safety feature

Laser safety box

DioScan Circular table
Short cycle time

Application

Sensors, electronic housings,

etc. Part holder

Laserline GmbH, Germany 20

Joining Techniques - Comparison

Ultrasonic Vibration
1-Step-Process 1-Step-Process
Mechanical Force Transmission Mechanical Force Transmission
US-Frequency in Weld Zone Vibration Forces in Weld Zone
All Thermoplastics All Thermoplastics

Laser
1-Step-Process
No Touch
IR-Radiation in Weld Zone
All Thermoplastics (optically suited)

Glueing Heat Plate

Multi-Step-Process 1-Step-Process
Glue Application through Nozzles Global Heating through Heat Plates
Most Plastics All Thermoplastics

Laserline GmbH, Germany 21

Joining Techniques - Comparison
Availability Laser
Diode Laser 100
US
Highest welding quality (visible joints, fluff free) VIB
Highly flexible (robot, axis-system, Gluing
quasi-simultaneous welding) 50

Part damage Flexibility

Availability 99.5 %
Gap-bridging 0

Wear-resistant tool

Gap-bridging Joint-quality

Scan system

Direct diode
laser

Laserline GmbH, Germany 22

Requirements from Industry

Vibration

Gluing
Requirements Characteristics
Failed parts 0 ppm Process control
Gap bridging Check of melting path
Gas proof
No damage to the part
Laser Endless weld-seams
Non-contact
No fluff in weld No vibrations
Any desired contour Maximum flexibility
Sensitive electronic parts Ultrasonic Local heat input

Heat Plate

Laserline GmbH, Germany 23

Weld Seam Geometry YAG vs. Diode Laser
Diode Laser Nd:YAG Laser
Diode Laser
w = weld zone Top-hat beam profile "
Homogeneous weld over
entire width of weld seam
Good weld seam control
Ideal for welds > 0.25 mm
w w width and larger areas
Weld seam dimensions. Advantages and Diode Nd:YAG
disadvantages of the different systems Nd:YAG Laser
< 0.25 mm. + +++
!-Structures, etc. Gau beam profile:
0.25 ...1.5 mm +++ ++ High central intensity limits
Sensors, small housings, welding with setting max. power
path
Higher risk of parts damage
< 1.5 mm +++ -
Large housings, broad area connections, Less homogeneous weld
contour welding
Ideal for micro structures
Large area welds ++ --
Plastic layers, plate material, foils < 0.25 mm width

Laserline GmbH, Germany 24

Influence of Power on Productivity

influence of laser power, material: PA6,

Quasi simultaneous welding weld seam length: 250mm
25 5
Almost constant path
energy without damage time(Ges.-Zeit
Potenziell for weld
[s])
20 4
to components scan speed
Polynomisch (v [m/s])
total time for weld [s]
Higher power and scan

speed [m/s]
15 3
speed result in reduced
welding time 10 2

5 1

0 0
High flexibility AND 50 150 250 350

high productivity laser power [W]

Laserline GmbH, Germany 25

Scan Software

Laser control by scan software

Graphical view of settings

User-/ Operator surface

Special mode for easy operation

(e. g. operator mode for 3-shift
production)

Contour flexibility, import of dxf, wmf,

bmp, plt, ...

Laserline GmbH, Germany 26

Prozess Monitoring

Mechanical Thermal Optical Software Visual

Setting path Pyrometer Back reflection Frame-Grabber CCD-Camera

sensor diagnoctics Alignment
beam

Laserline GmbH, Germany 27

Examples: Automotive Industry

Air Flow Sensor

Car Key
Schaltbox

Laserline GmbH, Germany 28

Examples: Automotive Industry

Electronic Housings

Automatic Gear Box

Laserline GmbH, Germany 29

Plastic Welding: Examples

Mats from plastic material Invisible weld seam in PMMA

Liquid pouring device Weld of foam on plastics

Laserline GmbH, Germany 30

Example: Magnetic Sensor

Welding seam
Photo: Laserquipment

Tyco Electronics AMP GmbH

Integration in a system with round switch table

Laserline GmbH, Germany 31

Example: Movement Sensor

LDL 40-100 - Direct Diode Laser

Contour Welding
Opaque Material

Source: Laserquipment

Laserline GmbH, Germany 32

Example: Hydraulic Tank

Welding of hydraulic tanks

DioScan 200

Result:

Excellent welding seam

Single step process

Highest process-stability

Non-contact process

No fluff development

Source: branson

Laserline GmbH, Germany 33

Example: Ostomy Bags

LDF 600-300
Fiber-Coupled Diode Laser

Medical Industry
Contour welding of concentric
Circles
Soft-to-soft welding

Laserline GmbH, Germany 34

Example: Filter Element

(1)
Medical Industry
Contour welding of
transparent material
Clear weld (1)
Black absorbing foil (2)
(2)

Source: Leister

Laserline GmbH, Germany 35

Reference Customers (selection)

Automotive
- Bosch
- Bremi
- Daimler Chrysler Sensors
- Geigertechnik Metal Welding Electrical-Mechanical
- Grau Components
- Mendiguren Plastic Welding
Valves
- Siemens VDO
Housings
- VAW

Others
- Boeing
- Colbond Metal Welding
- Erlas
Plastic Welding
- Philips
- Thyssen Pump-Module for Fiber-Laser
- TRW

Laserline GmbH, Germany 36

Outlook

Plastic Welding with Diode Laser

Highest Quality-Requirement for

Joining Techniques in Automotive
Industry
Easily Integrated in Full-Automation
Systems
Customers-Specific Solutions

Laserline GmbH, Germany 37