A single typical laser welding system can achieve output speeds 4-5 times faster than tungsten inert gas (TIG) and metal inert gas (MIG) processes, reducing manufacturing footprint and maintenance costs due to a laser’s non-contact operation. Laser welding solutions also have a variety of established in-process monitoring technologies so each weld joint can be individually evaluated for quality. The increased speed, reduced footprint and quality traceability make it an ideal candidate for industries like automotive, aerospace, and electronics, enabling the production of complex, high-quality components.
How can you unlock the full potential of laser technology for your application? It all starts with laser process development and finding the right hardware and process parameters to prove out your design.
What is a Laser Process?
A laser is a concentrated form of coherent mono-chromatic light. It’s a tool in which energy is concentrated quickly in a small spot to manipulate matter. The wavelength allows the targeting of different types of material. A laser process in the automation context is a standard routine given a set of input parameters the machine uses to work on a part or assembly. Selecting the appropriate laser power, spot size, wavelength, and interaction time enables various manufacturing techniques such as welding, drilling, cutting, etching, cleaning, sublimation, and advanced 3D printing. The versality of laser technology makes it an invaluable tool across many industries, driving innovation and efficiency in manufacturing processes.
In the automotive industry, laser welding is becoming an ever-increasing essential process for assembling car parts, from welding vehicle bodies to cutting and drilling various components. In eMobility or energy storage battery manufacturing, lasers are used to weld battery modules, tabs, and cases, ensuring strong and reliable connections.
Electronics manufacturers use lasers for etching and soldering, while aerospace uses lasers for the 3D metal printing of complex parts.
Benefits of Using Laser Processes
Laser processes provide significant advantages, particularly in speed and adaptability. Their non-contact nature allows for rapid and precise modifications without the wear and tear associated with traditional methods. This results in lower maintenance costs, as lasers typically do not require consumables.
Compared to traditional methods like TIG welding, laser processes are more accurate and repeatable. Previously challenging applications like welding copper-to-copper or dissimilar metals are overcome easily with the use of a laser. This opens up a realm of new possibilities in product design, as once difficult processes can now be achieved—driving innovation across eMobility, consumer electronics, automotive and aerospace industries.
The Importance of Tooling and Clamping
Tooling and clamping play a crucial role in laser weld quality and process repeatability (you can’t weld air!). Properly designed tooling and clamping systems are needed to securely position parts during the welding process and ensure intimate contact between the welded components.
Improper clamping can have a significant impact on the laser welding process. Misalignment can cause the parts to be welded outside of their positional tolerance. A loose fit can introduce air (porosity) into the weld joint and prevent the heat from being transferred from the top to bottom weld layer. This can lead to incomplete or weak welds, resulting in structural failures and compromised product integrity. Poor clamping can also introduce variability in the welding process, making it difficult to achieve repeatable results. This results in poor or defective welds, higher scrap rates, and increased production costs.
To avoid these issues, customized tooling and clamping solutions tailored to specific applications are essential for optimizing the welding process and ensuring consistent, dependable outcomes.
ATS Industrial Automation’s Approach to Laser Process Development
Our approach to laser process development begins with thoroughly understanding customer requirements, such as materials involved, desired weld strength, and specific application needs. Once this is clearly defined, ATS designs a tailored process and develops a pilot line to test and refine the solution before scaling it to full production. This process includes:
- Initial tests with representative sample materials to set laser parameters. This is typically a basic “bead-on-plate” test, whereby two representative raw materials (plates) are clamped together and welded using a single straight weld bead.
- Trials on single parts to validate the process on a smaller scale. In this step, ATS experts prove out the process and clamp on several parts, one at a time.
- Scaling up to handle multiple parts, ensuring production speeds and volumes are met. Clamping, tooling, and processes are updated to include an array of parts, validating that single-part parameters can be scaled.
Once the processes are proven, how do you go from lab to production?
Integration with the Entire Assembly Line
Integration with the assembly line is a critical aspect of laser process development. The end goal of your laser process shouldn’t be getting it to work in a lab, but in a production environment—24 hours a day, seven days a week. ATS ensures that tooling principles learned in the lab are transferable to a production space.
ATS designs laser systems to interact with fully automated systems by:
- Ensuring clamping securely holds and presents the part to the laser in a repeatable manner.
- Confirming parts can be transferred in and out of the laser system within the allotted cycle time.
- Utilizing advanced vision systems to locate the part.
- Using in-process weld monitoring techniques to verify weld quality.
Why Choose an Automation Partner for Laser Process Development?
Partnering with an automation company like ATS Industrial Automation for laser process development offers several advantages. First, you have the flexibility to select the best technology without being tied to a specific vendor. This ensures the most suitable laser equipment is chosen to meet the requirements. Additionally, automation partners deliver more than just equipment. Comprehensive solutions will seamlessly integrate laser technology into the entire assembly ecosystem, making sure all components work together effectively.
At ATS, we offer our expertise in high-speed, precision automation. Our team excels in designing laser processes and clamping systems that are fast, accurate, and can seamlessly integrate into the assembly line.
A High-Quality Laser Process Requires Early Development
Successful laser process development begins with early engagement. Addressing common questions about laser welding, material compatibility, and precision early in the process sets clear expectations and provides a strong project foundation. Early involvement in part design helps identify challenges and optimize designs for laser compatibility, ensuring materials, thicknesses, and geometries align with the laser process.
Collaborating with ATS Industrial Automation ahead of time means our experts can develop customized tooling and clamping solutions that achieve high-quality, repeatable results and provide feedback on product or part design. This proactive approach allows for a seamless integration of the laser process into the production assembly line, resulting in an efficient, reliable manufacturing process.
Every project is unique. Allow us to listen to your challenges and share how automation can launch your project on time.
Ben Thayer
Global Systems Engineering Manager
ATS Industrial Automation
Ben has over 15 years of experience helping companies across numerous industries automate their assembly systems. He's a proactive problem-solver with a passion for learning and exploring new technologies.
