16 minute read
WELDING: Materials
What is micro-welding and why is laser an ideal fit?
Emma Wood, Global Product Manager, Emerson
Laser welding does not generate particulates. This is especially important in the microfluidic systems used in many biomedical applications where narrow pathways could become contaminated or clogged by debris.
All Images courtesy of Emerson
Several of today’s advanced applications involving plastic components are also some of the smallest. Developing compact devices that contain sensors and other tiny, delicate internal elements is a high priority for designers and manufacturers, particularly in the automotive and electronics industries. The same is true in medical devices used for in-vitro diagnostics (IVD), vital-signs monitoring, and injection and inhalationtherapy applications.
There’s a lot of complexity — geometric and electronic — inside these small devices as manufacturers attempt to offer more features without increasing size. Product quality, durability, precision, and aesthetics are also critical objectives.
So, what is the ideal way to assemble these small yet significant plastic devices?
Many designers rely on microwelding laser technology as an alternative to conventional fasteners or adhesives. The precision and controllability of laser welding make it ideal for meeting the challenge of creating small and reliable joints. Such joints can be as short as a few tenths of a millimeter and as narrow as 100 μm in parts with a surface area the size of a postage stamp. Choosing laser There are several reasons why a laser is ideal for micro-welding, including the following.
Control. It’s possible to accurately control the power dissipation within the weld by varying the power of the laser source. In Through-Transmission Infrared (TTIr) laser welding, radiation travels through an IR-transparent part and heats the surface of the mating part, but only to a specified depth. Heating is precise and highly localized to the area touched by the narrow IR beam. This is critical for parts with small sections and thin walls,
and the resulting welds are nearly as strong as the parent material(s).
Particulate-free. The laser-welding process is non-intrusive, and parts typically exhibit excellent cosmetic properties, which are essential for small parts where a minor aesthetic flaw is obvious. Also, there’s no frictional motion between the parts, so the welds are entirely free of particulates. This is critical for components with narrow pathways (such as micro-fluidic systems used in many biomedical applications), which risk contamination or clogging from debris during the welding process. The precisely controlled heat and pressure are beneficial, minimizing the risk of polymer displacement or channel collapse.
Design flexibility. The versatility of the laser-welding process makes it ideal for assembling extremely small components. Weld lines that span different three-dimensional spatial planes can be problematic with other bonding methods but are joined easily with lasers. Lasers can bond several materials, such as thermoplastic elastomers and other soft plastics, including combinations of dissimilar materials. Intricate internal welds are also possible.
Gentle. Several small products — such as earphones, smartwatches, or automotive sensor packages — contain delicate electronic components that are easily damaged during assembly. Microwelding bonds sensitive electronic and mechanical without damage because there’s little movement of the parts during joining and no excitation or vibration. The welding machine parts make no contact with the weld line. Force is applied to hold the parts, but at non-critical areas or surfaces, protecting them from damage. Speed. Laser welding is virtually instantaneous, with reliable bonding in as little as 0.5 seconds, so it suits the high-volume production of small components. Unlike welders that focus laser light on only a small portion of the weld line at a time, simultaneous laser welding is an option that heats the entire weld surface at one time — dramatically reducing cycle time without compromising quality.
There’s increasing demand for smaller and more intricate plastic components, often housing sensitive electronics, in several important markets. Manufacturers are looking for systems that deliver strong, clean joints in a highly compact package that suits installation in automated process lines. Such a solution is found in laser welders that specifically target micro-welding applications.
There are solutions that address the challenges of micro-welding applications involving small and intricate plastic components. For example, the Branson GLX-1 laser welder is Industry 4.0/ IIoT (industrial internet of things) capable, delivering actionable operational data via OPC-UA interfaces.
2022 A D V E R T I S E M E N T
Vendors in the fastener industry
Emerson
Branson metal and plastic welding
technologies from Emerson support manufacturing efficiency and enable innovative new product designs in such markets as medical, automotive, electronics, packaging, and others. Emerson invented ultrasonic plastic welding 75 years ago and has since expanded its range of joining technologies to include vibration, laser and infrared plastic welding systems, and heat-staking equipment. Digital 66• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • controls ensure increased precision and quality, while providing data for process optimization and regulatory compliance. Branson application development laboratories help customers shape brilliant ideas into workable designs, bringing ready-to-manufacture products to market, quickly and sustainably. The global Emerson aftermarket network delivers expert maintenance, reliability, and performanceenhancement services. December 2022 www.fastenerengineering.com Emerson 120 Park Ridge Road Brookfi eld, CT 06804 Phone: 203-796-0400 Branson.Info@Emerson.com www.emerson.com/branson
2022 A D V E R T I S E M E N T Vendors in the fastener industry
Smalley
Founded over 100 years ago, Smalley has evolved to become the world leader in the manufacturing and development of Retaining Rings, Spirolox® Retaining Rings, Constant Section Rings, and Wave Springs. Smalley has led the way in introducing state-of-theart products and continues to lead the way in innovations for the future.
Smalley stocks over 10,000 standard parts across 30 configurations and 400 sizes. If a standard part doesn’t meet your requirements, you’ll work with our team of over 30 industry-specialized engineers to quickly create an economical custom part in the material of your choice, all without new tooling. Prototype or production volume, our No-Tooling-Charges™ manufacturing process meets the design flexibility your application, budget, and timeline requires.
While all of our manufacturing is made in our U.S.-based 300,000 ft2 facility, our global network of offices, engineers, and distribution partners allows you to receive parts and support from anywhere in the world quickly. Smalley’s dedication to quality and manufacturing excellence has earned us multiple service and quality awards and the trust of OEMs worldwide.
Smalley
555 Oakwood Road Lake Zurich, IL 60047
Phone: +1 847 719 5900 Email: info@smalley.com smalley.com
Selecting the Optimal Washer
J.W. Winco, Inc.
Flat: Generally used for load disbursement
Tab/Lock: Designed to effectively lock an assembly into place
Finishing: Often found on consumer products
Wave: For obtaining loads when the load is static or the working range is small
Belleville: Delivers the highest load capacity of all the spring washers
Fender: Distributes a load evenly across a large surface area
Shim Stacks: Ideal for simple AND complex applications Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377
(in the US & Canada)
bokers.com
Spring Loaded Devices from JW Winco
When you need to align, hold, or latch different parts of equipment together, you need a spring loaded device.These locking systems are designed to facilitate repetitive positioning operations on machines and equipment or parts undergoing machining. Spring loaded devices create a secure connection with limited play. JW Winco has many different versions and types for your application requirement.
Check out www.jwwinco.com to find out more!
J.W. Winco, Inc. Phone: 800.877.8351 sales@jwwinco.com www.jwwinco.com
Wide variety of spring to meet your innovation needs
When it needs a specifi c spring to empower mechanical function of your product for best performance, such as Tensioning & Loading, Counterbalancing, Retrieving & Returning, Drive Motor, you are welcome to contact design engineer of Ming Tai Industrial Company for best solution. Based on 60 years manufacturing experience of steel strip spring, well experienced engineers of Ming Tai Industrial Company are capable to provide you with the best solution to meet your innovation needs. to empower mechanical function of your product for best performance, such as Tensioning & Loading, welcome to contact design engineer of Ming Tai Industrial Company steel strip spring, well experienced engineers of Ming Tai Industrial Company are capable to provide you with the best solution to meet
Check out www.powerspring.com.tw for more interesting innovation stories!
Ming Tai Industrial Co., Ltd. No. 250, Sing Jhong Road Tamsui, New Taipei City 251 Taiwan Phone: 886-2-26228651 Fax: 886-2-26220202 E-mail: mtis@powerspring.com.tw
NBK Acquired Solid Spot’s Plastic Fastener Business and Expanded Lineup
NBK is a manufacturer of Specialty Screws including Plastic Fasteners. In this April, NBK acquired Solid Spot LLC’s plastic fastener business and then, more various product lineup are available such as PEEK, RENY, PC, PVDF, PTFE, POM, etc.
NBK manufactures not only plastic screws but also low profi le (low head), miniature size(less than M3), vacuum application, anti-galling, chemical resistance, non-magnetic, and more.
Flexible customization is available.
NBK America LLC 307 East Church Road, Suite 7 King of Prussia, PA 19406
A family-owned business since 1955, ND Industries
specializes in the development of innovative materials and processes which increase the safety and reliability of fastener assemblies. Headquartered outside Detroit, Michigan, ND serves a global market with divisions across the continental US, facilities in Taiwan, and licensees around the world. ND’s core business revolves around the application of a wide variety of custom formulated materials onto fasteners and assemblies to aid in functions such as locking, sealing, masking, lubricating, and noise and vibration damping. ND also manufactures a line of bottled adhesive and sealant products under the Vibra-Tite brand name for MRO and retail use.
ND Industries, Inc.
www.ndindustries.com info@ndindustries.com
Assemble Faster with SLIC Pins
Pin and Cotter All-In-One Eliminates Cotters, Clips, Nuts Speeds Assembly Time No Tools Needed Safer Retention, More Secure As Strong as Corresponding Cotters
The SLIC Pin from Pivot Point features a strong, spring-
loaded plunger that acts as an automatic cotter. Upon insertion, the plunger automatically ramps down to pass through the application, springing back up to lock the pin in place. More consistent and easier to install, SLIC Pins eliminate the wasted motion to install a cotter, clip or nut. With separate pin/clip systems, clips can be mis-installed, forgotten altogether, or fall o later. The one-piece design of a SLIC Pin eliminates those risks, reducing product failures in the fi eld and leading to a more consistent product. Manufactured on automated equipment, SLIC Pins are a ordable, making them an ideal solution for optimizing high-volume assembly.
Tens of millions of SLIC Pins are installed each year, touching every industry and saving countless hours.
Explore SLIC in your application today. Pivot Point, Inc.
SET SCREWS • HEX KEYS • SHOULDER BOLTS • NYLON TIP
• SOCKET CAP SCREWS • STAINLESS • METRIC / INCH •
ZINC PLATED SOCKETS • SHORT ARM HEX KEYS • 6-LOBE
SOCKETS • BUTTON HEAD CAP SCREW • DOWEL PINS •
IMPORT / USA • BRASS TIP • STANDARDS / SEMI-STANDARDS
• SQUARE HEAD SET SCREWS • HEX JAM SCREWS • LONG ARM HEX KEYS • NYLON PATCH • LOW HEADS 6-LOBE
(TORX) KEYS • BUTTON FLANGE CAP SCREWS
Please visit us at www.SetkoFasteners.com Setko Fasteners & Distribution 300 N. Klick St. Unit A • Hampshire, IL 60140
Fastener Engineering
This area has long been one of the most read and sought after by our engineering audience! From screws to bolts and adhesives to springs, these critical but often overlooked components are the key to every successful design.
FastenerEngineering.com will serve readers in the mechanical design engineering space, providing news, product developments, application stories, technical how-to articles, and analysis of engineering trends. This site will focus on key issues facing the engineering markets around fastener technology, along with technical background on selected components.
ADDITIONAL RESOURCES: • Special print section in select issues of Design World • Fastener Engineering monthly newsletter
Engineering
September 2019 A supplement of Design World
covering nuts, bolts, rivets, screws, u-clips, eye bolts, washers and more.
LEARN MORE AT: FASTENERENGINEERING.COM
AD INDEX
Able Electropolishing ......................... IBC Boker’s, Inc. ...............................................19 Emerson Industrial Automation .......38 J.W. Winco, Inc. ....................................... 57 Ming Tai Industrial Co., Ltd. ................. 9 NBK America LLC ...................................29 ND Industries .................................... 24,25 Pivot Point Inc. ........................................ 15 Rotor Clip .................................................IFC Setko Fasteners ..................................... 21 Smalley Steel Ring ............................... BC
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Ryan Ashdown rashdown@wtwhmedia.com 216.316.6691
Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055
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Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029
Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_mediaVendors in the fastener industry
Courtney Nagle cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel LEADERSHIP TEAM
Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich
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December 2022 www.fastenerengineering.com
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2022 Handbook Fastener
11/22/22 1:37 PM
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