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In plastic processing in industries such as aerospace, automotive, and electronics, welding quality directly impacts product reliability. However, traditional welding processes have significant drawbacks: ultrasonic welding's mechanical vibrations can easily damage internal components, while the high pressure of hot plate welding can cause cosmetic damage. Ordinary laser welding often suffers from insufficient weld strength and carbonization deformation, failing to meet the demands of precision manufacturing.
I. Core Pain Points and Causes of Plastic Welding
Low Weld Strength: Insufficient tensile strength in the weld joint leads to cracking and detachment, affecting product lifespan.
Poor Appearance Quality: Plastic is prone to carbonization and leaving marks during welding, failing to meet the appearance requirements of precision products.
Weak Process Stability: Mass production is easily affected by external factors, resulting in a high weld defect rate.
Inadequate Energy Efficiency: Traditional lasers have low electro-optical conversion efficiency, high energy consumption, and poor environmental performance.
The root cause lies in the compatibility between laser performance and the process: Uneven power distribution in ordinary lasers leads to uneven plastic fusion; improper matching of process parameters results in either insufficient heat causing incomplete melting or excessive power causing carbonization.
|
Comparison Dimensions |
Fiber Laser |
Semiconductor Laser |
|
Optimal Process Parameters |
Power 50W, Speed 30mm/s, Defocus -2mm; |
Power 60W, Speed 40mm/s, Defocus -2mm |
|
Maximum Joint Pull Force
|
89N |
154N (nearly 80% improvement) |
|
Power Distribution
|
Concentrated at the center of the beam |
Uniformly distributed within the beam area |
|
Core Advantages |
High beam quality |
Uniform heating; Large process window. |
|
Potential Issues |
Prone to plastic carbonization |
No significant weaknesses. |
Semiconductor lasers, with their uniform power distribution, effectively increase the fusion width at plastic interfaces and prevent carbonization, making them a superior choice for plastic welding.
Based on the core advantages of semiconductor lasers, DMK has thoroughly solved the three major challenges of plastic welding—strength, appearance, and stability—through technology integration and process optimization, providing efficient and reliable welding solutions for the precision manufacturing industry.