Defining Through Transmission Welding (TTLW)

When I went to your commercial web site, just now, I was hit with a virus warning.

You might want to check that out.

Something about JSAgent.NEJTrojan

Danger! Danger!

OK,

So, lasers cut and weld metals all the time.

Now they can weld certain types of thermoplastics.

What makes two different materials incompatible for this process?

The beam is very small and it can only travel so fast, but it has to traverse the entire length of the bond line. An ultrasonic welder can do it all at once.

Why is PMS or whatever, better?

In response to the virus threat you mentioned, I manage the site linked to in the post. I just looked into the problem and have corrected it. If it persists for anyone else viewing the post please let me know.

@Lyn - laser plastic welding has a few advantages in comparison to ultrasonic. For a complete breakdown, here is a good place to start.

Probably the most notable advantage of laser welding is the precise energy control. It creates a very localized heat affected zone, whereas ultrasonic welding can often overload a part with thermal/mechanical stress. This becomes important for intricate devices (medical, sensitive electronics housing) where the device itself can be damaged from the process.

Ultrasonic welding also leaves dust-like particulates and melt flash that can contaminate devices and or cause cosmetic defects, again very important in the high-cleanliness environments of medical device and electronics manufacturing. Laser welding leaves a very clean joint with no flash or particulates.

A few other highlights:

• Fast cycle times
• Flexible application changeover (contours can be changed within the software)
• Cosmetic appeal of joints
• Joint precision (beam spot sizes as small as 0.07mm can produce extraordinarily intricate weld seams)
• Minimal mechanical/thermal stress
• Complex contours

Disadvantages v. ultrasonic:

• Capital investment higher (laser is suited toward high-volume production, total cost of ownership is low as maintenance is minimal and cycle times are excellent, but the initial investment is higher)
• Learning curve to designing for laser (materials, joint design, process)

Laser plastic welding isn't going to replace ultrasonic outright, but it certainly opens up new opportunities and has potential for welding devices that ultrasonic can not. The markets that will make heavy use of laser welding are growing as well (medical device, auto electronics, consumer electronics).