LASERSYSTEMS

Laser welding of plastics.

Innovative and flexible.

2

Leister Corporate Center in Kaegiswil, Switzerland.

Leister delivers performances.Wherever you need to apply heat, Leister provides the ideal solution. We have been the worldwide leader in the field of plastic welding and hot-air blowers for over 60 years. In addition we have also beenoffering innovative and effective laser systems and micro-systems forseveral years. We develop and produce all of our products inSwitzerland – so you can always rely on the proverbial Leister quality.Because 98% of our production is exported, we have established adense network of service centers throughout the world – guaranteeingexcellent service anytime and anywhere.

Plastic WeldingFor decades now, we have beenthe worldwide market leader.The proverbial performance andreliability of our products makesLeister the first choice. Our toolsare used in roof sealing systems,floor coverings, plastic sheeting,in earthworks, hydraulic andtunnel engineering, in processequipment manufacturing andfor vehicle repair.

MicrosystemsIn tomorrow’s world, the smallestof structures will play a hugerole! In order for our customersto keep ahead of the field in thefuture, we are already developingand producing micro-mechanicalsensors and micro-optical com-ponents in our cleanroom today.

Process heatWhether for activation, heating,curing, melting, shrinking, weld-ing, sterilization, drying or warm-ing: hot-air is increasinglydeployed in industrial processes.Leister customers profit from ourextensive engineering knowledgeand benefit from our advice inthe conceptual design of hot-airapplications.

LasersystemsOur innovative solutions for pre-cision welding open up new pro-duction methods in automotivemanufacturing, medical and sen-sory industries as well as elec-tronic and microsystem techno-logies.

3

Laser beam

Transparent joining part

Absorbing joining part

Melt zone

Weld seam

The laser welding principle

In laser welding of thermoplastics, sometimes referred to as «laser transmission welding» or «through transmission IR welding»(TTIr), transparent and absorbing parts are bonded together. The laser beam penetrates the transparent plastic and is convertedto heat in the absorbing plastic. Since both parts are pressed together during the welding process, heat is conducted from theabsorbing to the transparent plastic, allowing both materials to melt and create a bond. In addition to the externally appliedclamping force an internal joining pressure is also generated through the thermal expansion of the laser-heated plastic parts. Theinternal and external joining pressures ensure strong welding of both parts.

Almost all thermoplastic plastics and thermoplastic elastomers can be welded with the laser beam – including ABS, PA, PC, PP,PMMA, PS, PBT as well as fiberglass reinforced plastic types. The achieved weld seam strength remains within the area of basicmaterial strength.

Joining pressure

Joining pressure

4

Medical: Clean and emission-freewelding

Automotive: High reproducibility andprocess reliability in alldimensions

Electronics: Vibration-free bonding without mechanical stress

Textiles: Continuous and fast joiningplastic films and fabrics

Plastics – laser welding brought to the point

Leister has been one of the world’s leading suppliers ofplastic welding equipment for many decades. A wealthof theoretical and practical knowledge of plastics

processing has been collected and is at our disposal. Leister revolu-tionized product assembly with the introduction of laser beamwelding. As evidenced by being one of the very first companies todevelop and manufacture laser systems for plastic welding, everynew development at Leister defines state-of-the-art possibilities.

Total customer focusIn our development laboratories, Leister scientists, engineers andtechnologists have developed a broad range of laser weldingconcepts, which have proven themselves in practice, time andtime again. We conduct research together with leading institutes,laying the foundation for developing tailored solutions for almostevery customer application. Leister is there to support you acrossthe board: from the concept, through design and material selection,right up to process optimization and integration.

This is what you get from LeisterAdvice:• Selection of the most suitable laser concept• Material selection assistance and weldability tests• Engineering and recommendation of suitable joining geometries

Development of processes and techniques:• Definition of the process window for all relevant parameters• Component testing and assessment of welding quality• Implementation of the process into the production environment

Prototypes and small series production:• Manufacture of prototypes• Pre-series and scale-up production

Bringing new techniques to maturityToday laser welding is a recognized joining technique for thermo-plastics. New applications are continually emerging while advantagesover traditional joining techniques are brought to bear. Laser tech-nology often provides solutions where conven tional systems havefailed or can be improved upon. Profit from our know-how, and letus test your application.

Nothing but advantages• Non-contact, flexible joining technique • Minimal thermal stress on the welded parts• Simple joining seam geometry• No particulate development• Vibration-free processing• Optically perfect welding seam• High precision• High strength• Gas-tight, hermetic seals• No tool wear• No consumables (adhesive, fasteners, etc.)

Suitable materialsNearly all thermoplastics and thermoplastic elastomers can be wel-ded with laser radiation – e.g. ABS, PA, PC, PP, PMMA, PS, PBT –even those reinforced with glass fibers. The achieved welding seamstrength is comparable with that of the base material.

The laser process requires a laser transmissive plastic to bebonded to a laser absorbent plastic, typically containing carbonblack. Special pigments also allow welding of dark/dark, transparent/transparent, and colored plastic combinations.

Laser systems from Leister are used in a wide range of industries.

Micro technology: Precise and localizedapplication of energy

Innovation is as much a tradition at Leister as practice proven, dependable Hot-Air tools that Leister produces for weldingplastics. Therefore the step to welding plastics with a laser beam was simply not only a logical progression, but it was also atechnological breakthrough.

5

Infusion pump(Contour welding)

Cerumen protectors(Mask welding)

Multi well plate(Mask welding)

Injection needle protection(Radial welding)

Optical sensor(Simultaneous welding)

Liquid vapor separator LVS(GLOBO welding)

Automotive tail light(GLOBO welding)

Oil cutter(Quasi-simultaneous welding)

Remote control(Contour welding)

Filter housing(Simultaneous welding)

Piezo valve(Quasi-simultaneous welding) Technical textile

(GLOBO welding)

Laser beams weld plastics.

Leister competently and flexibly addresses the literal diversity of the plastics industry in regard to materials and componentsand their design and size. With the versatile laser systems, the most diverse welding tasks are resolved individually and customerorientated. (concept discription p. 6 / 7)

6

Individual solutions for an extensive range of tasksLaser welding is suitable for diverse areas and applications. To be able to provide the optimum solution for every application,

Leister has developed various concepts. In this way the potential of this process can always be applied profitably. Leister offers

systems for Contour, Simultaneous, Quasi-simultaneous and Radial welding. The range of process is extended through the Leister

patented processes of Mask, GLOBO and Roller welding.

Contour weldingIn contour welding, a laser spot is guided sequentially along a pre-determined welding pattern, melting it locally. The welding volumeremains comparatively small as a result of the geometric conditions,and extrusion of the melt is avoided. Relative motion, is achievedby moving the component, the laser, or a combination of both.

Simultaneous weldingIn this technique, one or more lasers heat the entire weld pathsimultaneously. High power diode lasers are generally used as aresult of their compact design. It is very easy to achieve line-shapedwelding seams. Almost any beam geometry can be generated bymeans of special, state-of-the-art beam shaping elements.

Radial weldingA unique method for bonding cylindrical components whereby amirror deflects the laser beam such that it impinges radially on the outside symmetrical surface of the component. The tight (ID / OD)fit between the parts to be joined supplies the clamping pressurerequired for the welding process. The component remains in a fixedposition during the circumferential, continuous welding process.

Quasi-simultaneous weldingTwo scanner mirrors deflect the laser spot and guide it along the weld-ing contour at a very high speed. The joining surface is traversed several times per second, whereby the laser beam effectively heats and plasticizes the entire welding contour at the same time. Part tole-rances can be melted and collapsed forming a welding bead, as both joining parts are pressed together during the welding process.

Characteristics and application:• Laser beam focused to a spot• Ability to change weld width by varying focal distance • Arbitrary 2D joining line• Ideal for frequent changes of component

Characteristics and application:• Suitable for different diameters• No rotational movement• High throughput• No clamping device required

Characteristics and application:• Short processing time• No relative motion• Gap filling possible• Suitable for mass production

Characteristics and application:• Laser beam focused to a spot• Great flexibility• Gap filling possible• Suitable for small series and mass production

7

GLOBO weldingA laser beam is focused at a point on the joining plane via an airbearing, frictionless, freely rotating glass sphere. The glass spherenot only focuses – it also serves as a mechanical clamping tool.While the sphere rolls on the component, it applies continuouspressure at a point on the joining plane. The glass sphere replacesthe mechanical clamping device and expands the scope of laserwelding to both continuous and three-dimensional applications.

Mask weldingA mask is inserted between the laser source and the parts to bewelded. A curtain or collimated laser light is moved across theentire joining area of the parts. The laser is only incident on thecomponents where they are not obscured by the mask. Maskwelding achieves a very high resolution, and is suitable for straightand curved weld lines, as well as for two-dimensional structures.

Characteristics and application:• Line-shaped laser beam• Any desired joining geometry within a plane• Fast and flexible• Suitable for micro and macro applications

Characteristics and application:• Arbitrary joining geometries in two and three dimensions• Welding without a clamping device• Opt. synchronization of clamping pressure/ laser energy application• Suitable for robotic applications

The patented welding concepts Mask and GLOBO welding developed by Leister were granted the«Swiss Technology Award».

Roller weldingRoller welding is based on the concept of GLOBO welding. A linearlaser beam is focused through a glass roller onto the welding plane.The roller is optionally supported on one or two sides and the linewidths are available in various lengths. Roller welding enables widerweld seams and hence greater strengths in the weld zone.

Characteristics and application:• Any two-dimensional welding geometry along a line• Welding without clamping device• Different weld seam widths• Suitable for robotic applications

8

NOVOLAS Basic AT: Flexible, modular laser system for integration BASIC AT Compact : Compact and cost-efficient laser systemfeaturing an air-cooled diode laser

• Flexible and cost-effective; suitable for diverse applications

• Individual control via customer supplied guidance system

• Multiple laser and optic modules in one system possible

• Very high throughput possible with an appropriate upgrade

• Modular design with various optional components

CE listed. Technical data subject to change. Further options on request.

Technical DataLaser type diode laser, fiber laser

Beam shape spot or line

Laser power W spot up to 200, line up to 600

Line length mm 20 – 100, LineBeam AT

Multi laser up to 4 laser modules per system possible

Pilot laser / aiming laser mW < 3 (laser classes 2 / 2M)

Data interface digital / analog I /O, RS232, RS422 /485

Line voltage Basic AT V~ 200 / 230 ±10%

AT Compact V~ 110 – 230 ± 10%

Frequency Hz 50 / 60

Max. current consumption A 10 – 16 (depending on configuration)

Cooling water or air cooled, depending on configuration

Environment conditions °C 15 – 40, air cooled 15 – 35

Weight kg starting at 35 (AT Compact)

Laser class 4

The modular, integratable and powerful laser systemsNOVOLAS WS-AT, NOVOLAS BASIC AT and BASIC AT Compact: The combination of these laser systems with the laser welding

principles described gives rise to a multitude of options, ready to take on every challenge. Leister Novolas laser systems are

enhanced with comprehensive accessories matched to the systems. The accessories have been developed for varied applica-

tions, allowing you to assemble or retrofit a laser welding system specifically geared to your needs, applications and processes.

NOVOLAS BASIC AT and BASIC AT Compact

NOVOLAS Basic AT and Basic AT Compact are optimised for the inte-

gration into production lines and manufacturing cells. The laser systems

can be easily configured for various requirements, due to their conse-

quent modular design. Almost any welding concept can be realised

with the different diode lasers and optic modules. The mutually matched

components provide high process stability as well as cost-saving

production. The use of multiple laser and optic modules in one single

system enables an efficient way to increase throughput which also

helps reducing costs.

9

NOVOLAS WS-AT: Laser welding system, configured as a manualworkstation

CE listed. Technical data subject to change. Further options on request.

• Turn-key laser system for all laser-welding concepts

• Comprehensive and intuitive human machine interface

• Use of multiple laser and optic modules per system increasethroughput and efficiency

• Online process control integrated in system control

• Modular design for customization

• Easy to integrate into existing transfer systems

Technical DataLaser type diode laser, fiber laser

Beam shape spot or line

Laser power W spot up to 200, line up to 600

Line length mm 20 – 100 LineBeam AT

Controller PC control for laser, axes and process control

Multi laser multiple lasers per system possible

Pilot laser / aiming laser mW < 3

Data interface Windows Share

Control interface customer specific, Ethercat, Profibus, CAN,RS 232, Profinet, ...

Line voltage V~ 200 / 230 ±10%

Frequency Hz 50 / 60

Max. current consumption A 16

Compressed air connection bar 6

Cooling water or air cooled, depending on configuration,exhaust air max. 55 °C

Environment conditions °C 15 – 40, air cooled up to 35

Dimensions (B x D x H) mm standard model 860 x 1240 x 1860,without warning lamp and monitor

Weight kg approx. 400 (depending on configuration)

Laser class 1 (with pilot laser 2 / 2M )

NOVOLAS WS-AT

An all-modular, all-purpose system. It contains all components

necessary for processing and is ready for connection of all options.

You can therefore select any additional components necessary and

useful for your process. The NOVOLAS WS-AT laser system can be

used in combination with multiple laser modules and optic modules,

thus increasing productivity and efficiency of the production process.

Cycle times are optimized by implementation of a rotating table for

automated or partially automated handling of the components for

processing. The controlling software includes modules for process

control and is designed for integration of additional options and

accessories. An online process control with good/bad evaluation is

implemented in the control system. Immediately after installation of the

turnkey system you can start with production.

10

Optional components for NOVOLAS laser systems

The range offered by Leister Lasersystems is rounded off by a multitude of accessory parts co-ordinated with the systems.With these accessory components developed for various applications and requirements, the systems can be optionallyequipped according to customer specifications. For Mask welding, apart from the special line lasers, masks are also offeredwhich can be individually manufactured according to customer specifications. Special clamping devices and customer-specificoptics belong to Leister’s performance spectrum.

Standard optics

• A range of focal lengths

• Robust housing

• Fiber connection control

• Pyrometer optionally available

• Internal laser power measurement

GLOBO head

• Integrated optical and clampingsystem

• Glass sphere on air bearing

• Pneumatic clamping device

• Adjustable welding seam width

• Pyrometer optionally available

Ring optics

• Nearly any ring diameter

• Welding seam width is selectable

• Homogeneous energy distribution

Line laser LineBeam AT

• Line lengths 20 – 100 mm

• Laser power up to 600 W

• Very homogeneous energy densitydistribution due to special optics

• Pilot beam for adjustment

• Field lens optional

• Area lens optional

Roller optics

• Localized pneumatic pressure without additional clamping device

• Equalized pressure distributionby pivoting roller

• Different body configurations

• Line width range 3 – 30 mm • Single- or double-sided bearing-

mounted

Radial optics

• For rotationally symmetrical components

• Multiple diameters available

• Welding seam width selectable

• Laser safety can be integrated into optical head

Scanner optics

• F-Theta lense

• Working field 100 x 100 mm200 x 200 mm

• Constant focus diameter

• Weld contour selectable

• Pyrometer optionally available

Process control

• Pyrometer

Ñ Process control and adjustment according to temperatureÑ Temperature range 100 – 400°C

• Path/Force measurement

Ñ Process monitoring and control according to welding lengthÑ Resolution 0.01 mm at 25 mm measuring pathÑ Resolution 10 N at 2000 N measuring range

11

Faster and more economical ways to reach the goal

Those who use plastic welding technology know Leister. The leading supplier of innovative, practice proven and reliable devices.

Knowledge transfer for our customersWhether new plastics or new processes, our customers can restassured that Leister develops the appropriate devices, supportedby a worldwide service network. We have built up unparalleledknow-how in close cooperation with experts from various fields.Being one of the first companies to develop laser welding solutionsfor the plastics industry, we have compiled a vast amount ofexperience on this bonding method and are pleased to pass thisknowledge onto our customers.

Technology taken to maturityLaser welding technology is complex. Only through our customerfocus, as well as our plastics and processing experience, can we bring innovative techniques – such as Mask welding, Radialwelding, or GLOBO welding – to maturity. We are there to supportyou in all matters concerning laser welding – from the conceptionof a laser welding system to the welding process or to the selectionof suitable materials.

We capitalize process optimization Tap into our specialists’ knowledge and benefit from our optimallyequipped application laboratory. Together, let us optimize your pro-cess and integrate it into your production line. Our services includeconsultation, the development of processes and techniques, aswell as the manufacture of prototypes, production scale-up, andsmall series production.

Application support from A to ZWe are pleased to assist you in the selection of the most appropriate laser welding technique for your task. We supportyour engineers in the selection of the ideal material with weld abilitytests and can aid your designers in defining a joining geometrycompatible with the material and process.

Our know-how for your welding qualityWe can compile all the relevant parameters for you and define theprocess window in the course of developing processes and tech-niques. Our know-how is available for component testing and inthe assessment of welding quality. With our advice, you can rapidlyintegrate the laser welding system into your production line.

Anything is possibleWe are also there for you if you do not have the suitable infra-structure: We can manufacture prototypes and small series production for you in our application laboratory.

Besides state-of-the-art laser welding systems, we also offer a wide rangeof tests on material and components in our application laboratory.

Section through a laser welding seam of 3 mm width.

12

Hot-air and infrared radiation are frequently used for industrial process heat. If high power density or fine patterns are required,

these techniques are reaching their limits. It is for these applications that laser may be an option.

Laser for process heat: high power density applied with high precision

Surface absorption- Little reflection- Heavily absorbing material

ñ Surface layer is heated

Volume absorption- Little reflection - Slightly absorbing material

Reflection

ñMaterial is only slightly heated

Volume is heated

Whereas hot-air blowers and middle wave infrared systems achievea power density of 10 – 20 W/cm2, short wave IR or halogensystems achieve a power density of 100 – 300 W/cm2. If theapplication requires a higher power density, a laser is used. A lasersystem, however, achieves a power density of 100’000 W/cm2,thanks to its high focusability. With laser, process heat is appliedat high precision and can be applied locally.

The techniques also differ with regards to heat input. With hot air,the process heat is applied on the surface. A laser applies the heaton one specific layer of the surface or within the material, depend-ing on the wave length and absorption properties. In this case it isimportant that the radiation is not heavily reflected by the material.

Compared to infrared radiators, laser provides more power per area.Furthermore, laser can be used for delicate patterns. This solutionis especially interesting where process heat is used on limited areasof the surface layer. The fine patterning of the laser radiation can berealised by shading the beam with a mask.

Typical applications• Plastic welding• Remelting• Coating• Activation of surfaces

• Hardening• Joining• Softening• Triggering chemical reactions

• Selective desiccation• Soldering

Welding of GFK tapes. (pic.: MF-Tech, F, www.mftech.fr) Precise shrinking for sensitive parts.

13

Leister hot-air systems are deployed in countless industrial production processes. There is hardly an industry, which does not

profit from diverse advantages offered by our product portfolio – whether through cost-effectiveness or because many processes

simply become more efficient with hot-air.

Hot-air technology as an alternative

Know-howThe decades of experience in plastics processing and in industrialprocesses make us the ideal hot-air technology partner.

ConsultingAs worldwide market leader with our network of more than 120 salesand service centers in more than 90 countries, we are always localand can provide assistance at your location.

Extensive Leister product rangeEvery hot-air application in all industrial processes can be mat-ched with products from Leister. Our extensive product rangeincludes:

• Innovative, system-compatible air heaters • Powerful, robust blowers• Compact, flexible hot-air blowers• Combined air radiation heaters

• Comprehensive range of accessoriesCustomized solutions Along with our broad product range, we also offer productsdeveloped according to your individual specifications.

DevelopmentWe constantly develop and optimize our products. Our customersbenefit from continuous improvement, high supreme quality, relia-bility, performance and cost-effectiveness.

Application laboratoryOur application laboratory equipped with the most up-to-datemeasuring equipment is extremely well suited for simulating appli-cations and processes. With this service, we support you in findinga fast and efficient solution.

Independent safety testingAll Leister air heater and hot air blowers are tested by the inde-pendent test center “Electrosuisse”. Another feature to ensuretop quality and safety.

Combination options with air heaters, blowers and temperature controllers.

ROBUST high-pressure blower

Temperature measurement probe

Air hose

LHS 61L air heater

Control cable

Power cables

CSS EASY temperature controller

Alarm output

14

Leister Lasersystems is represented worldwide. Highly motivated and qualified sales partners are available to offer you advice.

They will accompany you during the entire process, from evaluation of the appropriate concept and system, via the test phase

and through to installation on site. But their assistance does not stop there: they will also be pleased to answer any questions

regarding technology for welding plastics using lasers.

Leister Lasersystems: international scope

Leister branches:

Germany

Leister Technologies GmbH AachenKontact: Carsten Thielen, Matthias Poggelcarsten.thielen@leister.commatthias.poggel@leister.com

USA, Canada, Mexico

Leister Technologies LLCKontact: Bill Millerbill.Miller@leisterusa.com

China

Leister Technologies Ltd. ShanghaiKontact: Cai Shengsheng.cai@leister.cn

Japan

Leister Technologies KK Yokohama / TokioKontact: Kenji Suzukikenji.suzuki@leister.com

Addresses of Leister distributors and partners:

Europe:

Germany

PPW Perfect Plastic WeldingContact: Dieter Wollstädter, Siegfried Kirchnerdw@ppw-systems.de sk@ppw-systems.de

HamecContact: Andreas Schochandreas@hamec.eu

Netherlands

Aeson AV Huizen /NLContact: Rudolf Dasbachr.dasbach@aeson.nl

Belgium / Luxembourg

HUPICO bvbaContact: Pierre Huyghebaertpierre@hupico.be

UK / Ireland

Horizon Instruments Ltd.Contact: Daniel Boltondbolton@horizoninstruments.co.uk

Denmark / Sweden

Weldingseller apsContact: Thorben Knudsentk@weldingseller.dk

France

Schloesser Prodeil (sales agent)Contact: Silvain Schloessers.schloesser@schloesser-prodeil.fr

Middle East:

Israel

Su-Pad (1987) ltd Contact: Ziv Sadehziv@su-pad.com

Asia:

Singapore / Malaysia

Long Shine Equipment & Supplies Pte LtdContact: Ivan Cheahivan@longshinegroup.com

Singapore / Malaysia / Thailand

MARM Technology Pte. Ltd.Contact: Matthew Fammatthew@marm.com.sg

Malaysia

SnR Gold Wave Resources Sdn Bhd Contact: Abdul Wahabawahab@snrgoldwave.com.my

Taiwan

GeniRay Technology Corp.Contact: David Hsudavid_hsu@geniray.com

Korea

YesLaser CorporationContact: Kerry Jungyes@yeslaser.com

15

Laser systems and components made by Leister have successfully been in use throughout the world for many years. You can

find a small selection of the numerous customers who put their trust in Leister here.

Leister Lasersystems: international success

®

www.leister.com/lasersystems

© Copyright by Leister

Leister Technologis KKShinyokohama Bousei Bldg 1F3-20-12, Shinyokohama, Kohoku-kuYokohama 222-0033 / Japan phone: +81 45 477 36 37 fax: +81 45 477 36 38 info@leister.co.jp

Headquarters:Leister Technologies AG Galileo-Strasse 106056 KaegiswilSwitzerlandphone: +41 41 662 74 74fax: +41 41 662 74 16leister@leister.com

Leister Technologies GmbHSteinbachstrasse 1552074 AachenGermanyphone: +49 241 8906 152fax: +49 241 8906 558info@leister-technologies.de

Leister Technologies LLC1275 Hamilton ParkwayItasca, IL 60143United Statesphone: +1 630 760 1000fax: +1 630 760 1001info@leisterusa.com

Leister Technologies Ltd.Building 11, 155 Yuanke RoadXinzhuang Industry ParkShanghai 201 109 /PRC phone: +86 21 6442 2398fax: +86 21 6442 2338leister@leister.cn

LASE

R / E

NG /

09.2

010

/ 10.

2012

/ Ar

t.-Nr

. 123

.141

Swiss Made Quality. Leister Technologies AG is an ISO 9001 certified enterprise. I Specifications are subject to change without prior notice.

Distributor’s address: