In conclusion, the 2 µm welding process represents a significant advancement in the field of laser welding technology. By allowing the joining of plastics without the need for additional absorbers, it opens new possibilities for manufacturers while maintaining high standards of quality and efficiency. As this technology continues to mature, its impact on industries such as medical technology, automotive manufacturing, and consumer product production is likely to grow, paving the way for innovative solutions in the future.

As the technology evolves, we’re witnessing an increase in the adoption of the 2 µm welding method across various industries. Companies are recognizing the benefits of improved weld quality, increased production speed, and reduced material waste. Furthermore, educational initiatives are providing engineers and technicians with the necessary skills to leverage this technology effectively, ensuring that the workforce is prepared for the demands of modern manufacturing.

Another special type of laser welding of plastics is the 2 µm process. This uses a laser beam with a special wavelength that is in the range of 1,500 – 2,000 nm (1.5 to 2.2 µm). This specific range is particularly effective for certain types of plastics, allowing for superior adhesion and strong welds that are critical in various applications. (Otherwise, welding is usually done with a wavelength in the range of 800 to 1100 nm). In recent advancements, researchers have explored how variations in this wavelength can further enhance the welding process, leading to innovations in both speed and quality.

ADVANTAGE: WITHOUT ABSORBERS

Understanding 2 µm Welding technology

With EvoClear (2µm process), two workpieces can be joined without an additional absorber, i.e., parts made of clear material, for example, as used especially in medical technology. This capability is revolutionary, as it enables the creation of products that require transparency, such as medical syringes and fluid containers, which can be crucial for monitoring medication levels. But laser welding of uncolored material is also possible, expanding its application to a wider range of industries, including automotive and consumer goods.

FIBER LASER FOR HIGH EFFICIENCY AND QUALITY

The main difference to conventional laser plastic welding lies in the way energy is introduced into the parts to be joined. The process exploits the property of most thermoplastics to absorb wavelengths above 1,500 nm (1.5 µm) more strongly in their uncolored natural state. This means that the energy is essentially deposited not just in the contact area of the two joining partners, but throughout the entire volume that is irradiated and penetrated. The laser beam enters at the surface of the plastic assembly and then continuously loses energy within the component, which leads to uniform heating.

In practice, this means that the 2 µm process can be tailored to suit specific material combinations, allowing for optimization based on the thermal properties of the plastics involved. Manufacturers can assess the melting points and thermal behavior of each material to determine the best welding parameters. Such customization has led to significant advancements in product design, enabling the creation of increasingly complex geometries that were previously difficult to weld using traditional methods.

Additionally, the 2 µm welding process is being explored in fields beyond traditional plastics. Research is underway into its application in biocompatible materials, which could revolutionize the production of medical devices. By understanding how different materials respond to the 2 µm wavelength, manufacturers can develop new products that not only meet stringent regulatory requirements but also improve patient outcomes through enhanced design and functionality.

Beam shaping plays a critical role in the heat introduced. In the joining zone, the energy density is so high that both joining partners are plasticized. In all other irradiated areas, the energy input weakens so that no plasticization occurs. This control of energy distribution is crucial in ensuring that the weld is strong and reliable, preventing potential failures that could arise from uneven heating. Furthermore, advancements in laser technology have allowed the development of more sophisticated beam shaping techniques, which can further enhance the precision and effectiveness of the welding process.

Beam shaping plays a critical role in the heat introduced. In the joining zone, the energy density is so high that both joining partners are plasticized. In all other irradiated areas, the energy input weakens so that no plasticization takes place.