Cost Comparison Is Laser Plastic Welding Economical?

Introduction
Laser plastic welding is becoming well known for its ability to join complex and detailed parts. In fact, the technology is driving innovation for products that were once not possible in the medical, automotive and consumer electronics industries. However, there still exists a stigma that laser technology cannot compete economically with other joining methods. Despite the technical advantages, the initial capital investment of laser systems has been a stumbling block for the technology. While there is truth in this and no laser system manufacturer will deny the higher investment, this is only one factor; many other substantial cost factors are often overlooked. This paper will introduce those factors and broaden the perspective regarding the total ownership cost of a laser plastic welding system. advancements and widespread adoption of lasers in many fields, not just plastic welding, the cost of laser sources have dropped significantly. Naturally this lends to a noticeable price decrease for the overall laser system. Although this change has yet to bring the cost of laser systems below those of other joining methods, the heavy weight of the initial capital investment is becoming more bearable. Much more bearable, in fact, once other advantages of the process are realized.

Total Cost of Ownership

When considering the total cost of ownership it is important to understand all of the cost factors involved in the system itself as well as process costs.

Laser Cost Advantages

The following is a breakdown of potential cost advantages for a laser plastic welding system. Cycle Time Laser plastic welding is capable of very short cycle times. This does depend, somewhat, on the laser process

Laser Sources Becoming More Economical

Typically the largest expense for any laser system is the laser source itself. However, with technological

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method (contour, scanner or simultaneous), but overall, laser has the potential to reach cycle times comparable to ultrasonic welding. Possibly of greater importance, laser welding does not require a time intensive annealing or curing step, drastically reducing the overall process cycle time and the need for additional equipment during this step. Also of note, is LPKFs hybrid welding process. Using halogen lamps to assist the laser in heating the plastics, cycle-times can be reduced by up to 50%. The halogen energy also helps soften the entire joint allowing for better part contact. Maintenance Laser systems are extremely low maintenance. A typical laser source can last 20,000 operating hours with virtually no maintenance. Systems are designed to run full-time and can be either manually operated or integrated into an existing automation system. The only scheduled maintenance on a typical machine is a recommended, annual change-out of the water filter for the laser cooler, a painless and inexpensive step. Quality Assurance Multiple process monitoring techniques give laser system users excellent quality monitoring capabilities. Pyrometer readings, reflection diagnosis, collapse monitoring and burn detection are tracked for each part. Parts that fail any of the above controls can be flagged for discard. Also, data for each part, good or bad, is stored for evaluation, allowing for process adjustments. The continuous measurements from this series of evaluation techniques lay out the platform for Six Sigma process performance analysis. Consumables Laser welding does not require any consumables. Common consumables for other joining methods include: adhesives, tapes, screws, rivets or filler plastics.

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Flexibility Switching applications for a laser system is often as simple as a quick clamp tool swap and the loading of a new process/parameter file. This can typically be done in less than a few hours. Extra Steps Avoided Because laser welding leaves clean joints there is no need for post-welding part cleaning. Also, as mentioned earlier curing and annealing steps are not required.

Laser Cost Disadvantages

Additives Most thermoplastics are naturally transparent to infrared laser energy; therefore, additives must be doped into the lower plastic layer to create absorptive properties. Fortunately, the most common, and best, absorbing additive is carbon black, a cheap additive that is already used to give plastics a black color. Part geometries The process of laser plastic welding requires excellent contact between the two joining parts. Because of this, part tolerances are very strict for laser plastic welding. Warpage and gaps in the parts can result in poor weld quality where the joint is not in adequate contact. Although not a significant difference this may result in higher costs, as more stringent requirements will be required of the injection molder.

Equivalent Cost Factors

Labor Actual operation of laser systems does not require any special technical skills, once the process software and tooling is set-up by the engineer. Therefore, laser systems require no more man power or expertise than any other method.

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Conclusion
In summary, laser plastic welding is well suited for high volume applications, where process cost savings can outweigh the initial capital investment. When neither speed nor quality can be sacrificed laser plastic welding provides an excellent solution.

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Author
Josh Brown Marketing Development Representative LPKF Laser & Electronics

About the author

For general questions or information regarding design and feasibility, please contact: Josh Brown Marketing Development Representative LPKF Laser & Electronics North America Email: jbrown@lpkfusa.com | Direct: 503.454.4231 Check out -> www.laserplasticwelding.com , your laser plastic welding resource. For general questions or information regarding design and feasibility, please contact the author. Dont forget to download a copy of LPKFs Laser Plastic Welding Design Guidelines, a document for engineers and designers in the concept and design stage of an application. Download the PDF now!

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