LPKF Laser Plastic Welding The Most Efficient and Secure Plastic Joining

Lars EderlehMarkus König

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Contents

4 What is Laser Plastic Welding? 6 Laser Welding Systems 18 LPKF Software20 Application Center21 Service and Support22 LPKF Worldwide

Better Products with LPKF Laser Plastic Welding

Laser plastic welding impresses with numerous benefits. It is particularly clean, precise, gentle and economic. If quality counts, nothing can beat laser plastic welding. LPKF’s system portfolio includes laser systems for reliable welding of very small or large parts, with welding seams from 100 µm up to several millimeters. These systems work stand alone, or they can be integrated into a production line.

Please be invited to get a short overview of LPKF’s laser plastic welding systems. Should you have any questions or would you like to receive a sample of welded parts, please feel free to contact your LPKF sales representatives. We are looking forward to be at your service.

Lars Ederleh

Managing Director

Markus König

Managing Director

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What is Laser Plastic Welding?

In many areas of application, laser plastic welding is replacing conventional joining processes such as gluing or ultrasonic welding. Production is being increasingly converted to efficient laser welding technologies in cost- and quality-sensitive sectors including automotive, medical and consumer goods.

A molded part made of material transparent to the laser wavelength is joined to an underlying component which absorbs the laser energy. The laser beam is focused through the laser-transparent part onto the absorbing part where it melts the surface. The upper component is pressed on with a defined force and itself becomes plastified by thermal conduction.

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This creates a reliable welding seam without harming the surface. Laser plastic welding enjoys many advantages: cheaper tool holders, easily programmable welding contours, and intelligent process monitoring during the welding process. Laser plastic welding leads to low reject ratios and a hygienic, absolutely particle-free, and attractive joining result.

Process parameters Laser power [W] Speed rate [mm/s] Joining pressure [N/mm²] Material properties

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Laser Welding Systems

LPKF InlineWeld SystemsIntegration systems for laser plastic welding

LPKF PowerWeld 2000 LPKF PowerWeld 6600Stand-alone systems in compact housings for small parts

Stand-alone systems in compact housings for medium parts

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LPKF TwinWeld3D 6000 LPKF TMG 3Stand-alone laser welding systems with robot-guided laser head for reliable and quick 3D welding

Stand-alone or system-integrated transmission test for plastics

LPKF PowerWeld3D 8000Stand-alone laser welding systems with the patented wobble welding process for large parts

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LPKF InlineWeld Systems

The systems in the LPKF InlineWeld series are designed for integration within customer’s production lines. The machine’s supply equipment such as laser source, power supply, cooling and the controls are housed in a separate switch cabinet. This makes the actual processing unit very small and flexible so that it can be easily integrated within automatic workpiece carrier systems or at a rotary table.

The LPKF InlineWeld Systems use a scanner based laser to generate arbitrary welding seams. Changes to the control data allow straightforward adaptation of the welding contour. The robust construction and the integrated clamping mechanisms make integration systems very valuable.

Automotive seating comfort device Welded display of a process control unit

for a forklift

Topping for a bedside infusion management

system

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The LPKF PowerWeld stand-alone machines were designed to be an economic solution for a wide spectrum of plastic welding specifications. The laser, control unit and cooling unit are integrated into a compact housing. Different laser sources and feeding systems like round indexing tables, combined with efficient controls and process monitoring systems ensure optimal workpiece quality and productivity.

High quality components ensure maximum machine availability, while integrated online process monitoring assures product quality. As modular solutions, they can be easily adapted to meet specific customer requirements.

LPKF PowerWeld Systems

Lab-on-a-chip: Microfluidic sensor Valve parts – welded and unwelded Safe joining of consumer products

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The LPKF PowerWeld3D 8000 has been especially developed for mass production of large welded plastic parts such as vehicle taillights. In a quasi-simultaneous welding process, weld seams with varying widths and homogeneous temperature distributions can be generated. Local tolerances of the joining material are smoothed out by the system.

This machine can weld parts with dimensions of up to 1000 x 750 x 400 mm. Joint monitoring provides for quality control. This ensures that the joined parts are reliably bonded and can be used even in areas requiring an IP67 rating.

LPKF PowerWeld3D 8000

Automotive tail light Backlighted door sill of a premium class car

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The LPKF TwinWeld3D is perfect for the industrial production of large 3-dimensional components at low unit costs. The innovative laser hybrid welding produces optically and mechanically enhanced welding seams, higher processing speed, and new options for designers and engineers. The innovative process increases flexibility and decreases tooling costs for fixtures.

The TwinWeld3D systems feature a new joining technology. Hybrid welding combines a laser with an additional heat source by halogen emitters. Whilst the laser light passes through the transparent upper welding partner almost unhindered, the heat field generated by the halogen spotlights give rise to a homo-geneous temperature gradient. LPKF assembles the complete welding head on a multi-axis robot.

LPKF TwinWeld3D Systems

Automotive tail light The patented laser hybrid welding process takes place in a thermal field

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The laser plastic welding process needs two parts with different absorption rates. The upper part has to be at least particularly laser transparent. If the absorption rate changes significantly, the process can fail.

The LPKF TMG 3 transmission tester determines the amount of laser radiation transmitted through a sample of plastic pursuant to DVS Regulation 2243. The device detects transmission fluctuations between components with an accuracy of ≤ 1 percent, and is insensitive to interference of ambience light. The LPKF TMG 3 can be integrated into a LPKF laser welding system or can be used stand alone. The data can be stored or used for tracking & tracing.

LPKF TMG 3 – Calibrated Transmission Testing Device

Certified calibration routine and measurement precision, ensures

stable results over multiple TMG devices and comparable readings

at different locations all over the world

Alfred-Nobel-Str. 55-57 D-90765 Fürth Tel. +49 (0)911 - 669 859-0

Fax +49 (0)911 - 669 859-77 E-Mail: info.laserwelding@lpkf.com

Sitz der Gesellschaft: Fürth Amtsgericht Fürth, HRB 14026

Steuer-Nummer: 218/131/70172

USt-ID-Nr.: DE289091188

Geschäftsführung: Markus König Lars Ederleh Commerzbank AG IBAN: DE90 2504 0066 0134 3433 00

BIC: COBADEFFXXX

Kalibrierzertifikat TMG 3 / Calibration certificate TMG 3

Gerätebezeichnung / Device name:

LPKF Transmissionsmessgerät TMG 3 / LPKF transmission measuring device TMG 3

Geräteseriennummer / Machine series number: 123456

Zertifikatnummer / Certificate number: 123456 / S 17

Messbereich / Measuring range:

0 … 100 % Transmission @ 980 nm / 0 … 100 % transmission @ 980 nm

Die für die Kalibrierung verwendeten Messnormale wurden durch die Physikalisch-Technische Bundesanstalt Braunschweig (PTB) kalibriert. Das PTB erfüllt die Anforde-

rungen an Kalibrier- und Prüflaboratorien auf Grundlage der DIN EN ISO/IEC 17025.

The measuring standards for calibration are calibrated by the national metrology institute of Brunswick (“Physikalisch-Technische Bundesanstalt Braunschweig”, PTB).

PTB meets the requirements for calibration and test laboratories based on DIN EN ISO/IEC 17025.

Verwendete Messnormale / Applied measuring standards

Art d. Messnormale / Type of measuring standard: Neutralglasfilter, AR-beschichtet / Neutral density filter, AR coated

Kalibriergegenstand / Calibration object: Spektraler Transmissionsgrad τ(λ) / Spectral transmittance: τ(λ)

Kalibrierzeichen / Calibration reference: 87652 - PTB - 16 - bis 87657 - PTB - 16

Ergebnisse der Kalibrierung / Calibration results

Standard T 3,89

T 10,23 T 29,6

T 42,5 T 59

T 75

Transmittance [%] 4,204

11,06 26,62

44,71 61,79

80,05

C [%]

4,200 11,00

26,66 45,16

62,26 80,40

C - IST [%]

-0,004 -0,060

0,040 0,450

0,470 0,350

UC ( C) [%]

0,000 0,000

0,024 0,024

0,068 0,000

Utot [%]

0,060 0,130

0,256 0,365

0,468 0,527

𝑋𝑋𝐶𝐶 : Mittelwert Kalibrierung / Average calibration value, Utot: Absolute Messunsicherheit / Absolute measurement uncertainty, 𝑈𝑈𝑡𝑡𝑡𝑡𝑡𝑡 = 𝐹𝐹 ∙ 2 ∙ √(𝑈𝑈𝑁𝑁2 + 𝑈𝑈𝐶𝐶

2), F = 1,

UN: Unsicherheit Normal / Uncertainty normal, UC: Unsicherheit d. Mittelwerts Kalibrierung / Uncertainty average calibration value,

Das Gerät entspricht zum Zeitpunkt der Prüfung der Herstellspezifikation. / The device complies with the manufacturer specifications as of

testing.

Kalibrierdatum / Date of calibration: 01-Jan-17

Nächste empfohlene Kalibrierung / Next recommended calibration: 01-Jan-18 Prüfer / Validator: ____________________

0,9500,9550,9600,9650,9700,9750,9800,9850,9900,9951,0001,0051,0101,0151,0201,0251,0301,0351,0401,0451,050

4,20411,06

26,6244,71

61,7980,05

tran

smitt

ance

[%]

transmittance setpoint [%]

normalized calibration valuereference

± 0,5 % mark± 1 % mark

± 1,5 % mark

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The software used for configuration is very important for complex processes. It is not only essential for ensuring the production success, but also vital for the flexibility of the whole system. The new LPKF ProSeT 3D software is significantly improving the set up of welding contours.

Benchmark setting new routines ensure that the processing software gets the maximum out of laser plastic welding. Smart assistants take over complex optimization work from the operator.

This software has been developed especially for laser plastic welding. It is able to take over 3D CAD data, and to incorporate it in calculating the welding process.

LPKF Software ProSeT 3D and WeldPro

ProSeT 3D imports and takes over Step files, DXF data and process

data from previous LPKF programs, and makes them available as

separate layers

Zones with different laser parameters are easily identified by the

different contour colors

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More than just laser systems: LPKF supports clients in finding optimal production processes. Physicians and application specialists are ready to help LPKF’s customers by testing new materials and designs. They develop optimized production processes to get the best product at lowest costs.

To ensure this, LPKF operates Application Centers in North America, Europe and Asia, equipped with the latest LPKF laser technologies.

Application Center for Evaluation and Consultancy

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Service and Support

Laser Systems for the World MarketLPKF is active in laser material processing for many years – with high performance systems for industrial production. The Laser Welding Division combines its own development potential with global mass production experience.

Full Round-the-Clock ServiceThe clients of LPKF enjoy full round-the-clock service to guarantee optimum availability of their equipment. Service technicians and engineers are available for commissioning the LPKF welding systems and to ensure that production starts smoothly. When the welding systems are running, highly qualified service staff provide professional support via hotlines, remote diagnosis, or on-site trouble shooting. Globally distributed warehouses ensure the immediate supply with quality spare parts.

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LPKF Worldwide

Headquarters LPKF Group LPKF Distributors

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LPK

F AG

, 051

017-

EN

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.jenk

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de

LPKF WeldingQuipment GmbH

Alfred-Nobel-Str. 55 – 57 90765 Fürth Germany

Phone +49 (911) 669859-0 info.laserwelding@lpkf.com

www.lpkf.com

Part of LPKF Group

Please feel free to contact your LPKF sales representatives:

sales.laserwelding@lpkf.com

LPKF provides worldwide

premium customer

support. Learn more:

www.lpkf.com/support

LPKF Service & Support