Laser Welding
High-density fiber laser welding offering minimal thermal distortion, deep penetration, microscopic seam widths, and the ability to join thin-walled and dissimilar metals.
Advanced Laser Welding Solutions
Laser welding represents the pinnacle of thermal joining technology. By concentrating a tightly focused laser beam onto the seam, metal is melted instantly with localized heat input that cools rapidly. This produces an exceptionally high aspect ratio weld (deep and narrow) with virtually undetectable thermal distortion on adjacent features.
Advantages Over Traditional TIG/MIG Welding
- Minimal Thermal Distortion: Sensitive electronic components or heat-treated assemblies can be joined without thermal degradation.
- Hermetic Seals: Capable of leak-tight welds exceeding Helium mass spectrometry vacuum standards.
- Zero Filler Material: Autogenous welds maintain alloy purity without adding weight or foreign chemistry.
- Repeatable CNC Automation: Consistent seam geometry across thousands of cycles with full robotic traceability.
Compatible Materials & Alloys
Our laser systems are optimized with assist gases (Nitrogen, Oxygen, Shop Air) and beam frequency controls for clean cuts across:
Typical Industrial Applications
- ✓ Hermetic sensor packaging and battery busbars
- ✓ Medical endoscopic tools and surgical implants
- ✓ Aerospace instrumentation and capillary tubes
- ✓ Automotive injector and exhaust sensor assemblies
- ✓ Tool and die repair and precision edge build-up
Engineering Tolerances & Capability Guide
| Material & Grade | Thickness / Envelope | Feature / Geometry | Standard Tolerance | Process & Assist Notes |
|---|---|---|---|---|
| Stainless Steel (304L / 316L) | 0.002" foil to 0.200" plate (0.05mm - 5mm) | Seam width & penetration depth | ±0.002" (±0.050mm) seam position | Continuous fiber laser with Argon shielding |
| Titanium (Ti-6Al-4V Grade 5) | 0.010" to 0.125" (0.25mm - 3.2mm) | Hermetic capillary & sensor tube joints | ±0.0015" (±0.038mm) | Trailing argon purge glovebox shielding |
| Dissimilar Copper to Steel / Nickel | 0.005" to 0.080" (0.12mm - 2.0mm) | Battery busbar tabs & shunts | ±0.002" (±0.050mm) | Wobble laser beam oscillation to prevent intermetallic embrittlement |
| Tool Steels (H13, S7, P20) | Micro-weld deposition (0.005" - 0.060") | Cavity edge repair & mold parting lines | ±0.001" (±0.025mm) deposition accuracy | Pulsed Nd:YAG / Fiber with micro-wire feed |
* Tighter non-standard tolerances available upon engineering review. Contact our quality department for specific GD&T and CMM inspection requirements.
Frequently Asked Technical Questions
How does laser welding compare to conventional TIG welding?
Laser welding delivers a heat-affected zone (HAZ) that is up to 90% smaller than conventional TIG welding. Because heat input is localized and cooling is rapid, thermal distortion is virtually undetectable, eliminating post-weld straightening and secondary machining.
Can laser welding join dissimilar metals like Copper to Aluminum or Steel?
Yes. By using advanced high-frequency optical oscillation (wobble welding) and precise laser pulse shaping, we successfully weld dissimilar metals such as copper-to-aluminum EV battery tabs and copper-to-stainless terminals without forming brittle intermetallic phases.
Are your laser welds leak-tight and hermetically sealed?
Yes. We regularly produce hermetically sealed enclosures, medical sensors, pressure transducers, and vacuum chambers that pass Helium mass spectrometer leak testing down to 1x10^-9 mbar·L/s.
Is filler wire required for precision laser welding?
Most laser welding is autogenous (fusion without filler metal), which maintains strict material purity, zero added weight, and pristine aesthetics. For tool-and-die repair or gap-filling applications, we utilize microscopic filler wires down to 0.005 inch diameter.
Have CAD Files Ready?
We accept STEP, STP, DXF, DWG, AI, and PDF drawing packages for instant tooling & turnaround evaluation.