Next-Gen beam shaper from Midel Photonics enables laser welding of complex plastics in Evosys systems. Evosys and Midel Photonics have collaborated to develop a welding process for high-performance plastics and engineering thermoplastics.

Challenge

In the automotive industry, the demand for complex plastic components is increasing – for example for fluid lines in electric vehicles. These components can withstand high temperatures, pressure and chemical stress, but their advantages go hand in hand with more demanding processing.

For some particularly challenging assemblies, laser welding processes reach their limits. Thermal defects, incomplete weld seams and high reject rates can make economical series production difficult or even impossible. Impurities in the material also pose a challenge in some cases. However, as laser welding is the joining process of choice for many OEMs due to its high quality, Evosys is continuously working to meet the challenges of new materials with innovative solutions.

“We see time and again that complex processes cannot yet be processed satisfactorily with conventional laser beams. This is exactly where we come in with Midel Photonics.” Frederik Wolf, Managing Director and Co-Founder

The joint solution

In the new cooperation, the high-precision machine platform from Evosys has therefore been upgraded with beam shaping technology from Midel Photonics.

“We were impressed by how easy it is to integrate the optics into our machines and even retrofit existing systems.” Lea Kroth, Project Manager Development at Evosys

With the help of Next-Gen beam shapers, the intensity profile of the laser is adjusted so that the energy is optimally distributed in the workpiece – in the right direction for the material, controlled and perfectly adapted to the individual welding process.

Component without beam shaper / with torch (top) and with beam shaper / without torch (bottom)

The future: laser welding even for the most complex plastics

  • New laser parameters expand material selection: Welding of high-performance plastics and technical thermoplastics possible
  • Stable, reproducible weld seams even with complex geometries
  • 0% defective and quality requirements for automotive and medical series production fulfilled
Next-Gen beam shapers can be integrated into Evosys standard process modules

Conclusion

The use of next-gen beam shapers enables stable, efficient welding processes for plastics that could not previously be welded with lasers. Together, Evosys and Midel Photonics show how beam shaping can open up new potential in plastic laser welding – economically, with high quality and suitable for series production.

The cooperation partners

Midel Photonics GmbH, founded in 2022, revolutionizes industrial laser material processing through innovative beam shaping. The multi-award-winning high-tech company sets new standards in precision and efficiency. With over 75 individually developed optical solutions, the experienced specialists create decisive competitive advantages for customers around the world.

Evosys Laser GmbH has been developing and manufacturing customized systems for the laser welding of plastics at its Erlangen site for 10 years. With the many years of market and process experience of its employees, the company offers creative and innovative solutions for integration into automation solutions worldwide.