Overview of Laser Welding Technologies
Dukane Intelligent Assembly Solutions provides a variety of laser welding technologies to tackle different plastic assembly challenges. The document details the capabilities and applications of Diode, Nd:YAG, and CO2 lasers, each with unique wavelength and power characteristics suitable for specific applications.

Laser Types and Applications

• Diode Lasers: Compact, cost-effective, operating at 808 and 940 nm wavelengths, suitable for various power levels.
• Nd:YAG Lasers: Utilize a solid rod of rare-earth material, producing 1064 nm light, suitable for broader applications with higher power levels.
• CO2 Lasers: Effective for welding thermoplastic films and cutting thermoplastics, available in high power levels for fast weldline speeds.

Beam Delivery Methods

• Direct Beam Delivery: Optics mounted directly on the laser housing, used in systems with movable parts or robot arms.
• Fiber Delivery: Allows beam delivery to tight spots, useful for Nd:YAG or Diode beams in automated machines.
• Galvo Heads: Enable fast steering of laser beams for complex operations, can be mounted on moving elements or robots.

Integration and Control
Dukane's software tools facilitate the integration of laser beam controls with positioning systems, ensuring robust processes and maximized part quality. Beam splitting allows efficient welding of larger parts by dividing a single high-power beam into multiple beams.

Enclosures and Safety
All laser systems require Class I laser-tight enclosures with laser-safe glass viewing windows. Guillotine doors provide access for operation and setup.

Through Transmission Infrared (TTIr) Process
This process involves sending an intense light beam through a transmittant part to be absorbed by an absorptive part at the weld interface, causing intermolecular mixing and forming a strong weld joint.

Advantages of Laser Welding

• Precise and controllable process with no flash or particulate outside the joint.
• Capable of producing aesthetically pleasing joints on complex geometries.
• Dust-proof, humidity-proof, and crack-resistant joints.
• Cost-effective with relatively inexpensive dedicated tooling.

Technological Integration
Combining robotic or servo technology with laser welding allows for flexibility in part design and the ability to weld large and complex parts efficiently. The document emphasizes the versatility and capability of laser welding, highlighting its cost-effectiveness and potential for combining various motion control technologies and beam delivery methods.

Galvo Heads and Laser Beam Steering
Galvo heads are crucial for steering laser beams at high speeds, enabling complex contour operations or quasi-simultaneous tasks. They can be mounted on moving machine elements or robots and are capable of distributing a fiber-delivered beam. Integration with beam or part positioning systems is facilitated by Dukane’s software tools, ensuring robust processes and maximized part quality.

Beam Splitting for Large Parts
Beam splitting is advantageous for welding larger parts, allowing a single high-power laser beam to be divided into multiple beams. This enables multiple-part production from a single motion source or the attachment of multiple galvo heads to a single laser for quasi-simultaneous welding. This method is cost-effective as the cost-per-unit-power decreases with larger laser sizes.

Positioning Systems
Positioning systems range from simple servo stages or galvo heads to complex robotic installations, tailored to meet specific needs.

Enclosures for Safety
Enclosures are mandatory for laser systems in factory environments. Dukane provides Class I laser-tight enclosures with laser-safe glass viewing windows and guillotine doors for access to the fixturing area, ensuring safety during operation, setup, or automated parts handling.