Automotive Thermal Management

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Use of plastics to reduce weight, increase yields, reduce warranty costs, and increase the reliability of thermal management components and system

The use of thermoplastics in automotive thermal management systems and components is growing as automotive design engineers look for ways to enhance safety, increase energy efficiency in electric vehicles, or reduce emissions of internal combustion engines.

Laser plastic welding is the perfect assembly technique for the automated assembly of thermal management modules for weight savings, reduced bills of materials, more robust assemblies, and reduced assembly times.

Component manufacturers use laser plastic welding to seal covers on plastic electronics enclosures and in fluidic and gas subassemblies integrated into thermal management mechatronics, battery management, fuel systems, air conditioning, electric motors and engine controls.

Welding Engineering Polymers

Laser plastic welding can weld any thermoplastic polymer, including up to 30% glass filled, high-temperature engineering polymers like nylons; PA-6, PA-66, PBT, PET, PC, PBT/ABS alloys, and many others.

Significant Benefits of Laser Plastic Welding for the Assembly Automotive Thermal Management Components

Laser plastic welding offers a high degree of flexibility to rapidly and inexpensively change over to new designs and adapt to new product form factors by changing the tooling, uploading the latest CAD into the machine, and changing tooling.

Laser plastic welding machines are available in the right size to fit your needs, with welders to accommodate part sizes from 100 mm x 100 mm to 1,000 mm x 750 mm.

Key Advantages for Laser Welding of Thermal Management Components

Particle Free - Laser plastic welding is a particle-free joining process compared to ultrasonic or vibration welding, so your assembly process will not contribute to particulate contamination from the manufacturing process.

Exceedingly Strong - The dynamic process of quasi-simultaneous welding supplies additional material to the joint, much like a welding rod in metal welding, to create joints that exceed the strength of the molded parts themselves.

Significant Savings on BOM and Labor - Laser plastic welding assembly allows designs without screws, reducing the bill of materials (BOM) and, therefore, costs compared to components secured with screws. Eliminate screws and bolts to speed and automate assembly.

Laser plastic welding is a faster assembly method than UV-cured adhesives and eliminates the costly maintenance and mess of glue dispensing and curing.

Fast Cycle Times - Depending on the part size, laser plastic welding machines from LPKF have cycle time from a few seconds on small parts (100 mm x 100 mm) to under a minute for large parts (500 x 350 mm).

Laser Welding Machine Configurations

LPKF has a wide range of highly flexible, standardized machines with custom tooling to rapidly change from one part to another with a simple CAD import and quick-change tooling.

Laser welding machines come in four different standard sizes to match your part size and budget.

LPKF has a complete line of standalone and integrated laser plastic welding solutions to fit your R&D, development, and low to high volume manufacturing requirements.

Custom Solutions

LPKF also offers custom engineered solutions with multiple lasers, mirrored tooling, clamping systems, and conveyor systems that are turnkey drop-in solutions.

Managing Risks

LPKF systems are backed by process development, prototyping, and validated production recipes, so you don’t have to worry about laser welding details. Let LPKF worry about the welding, so you don’t have to.

LPKF’s Getting Started program provides you with rapid material tests, design evaluations and guidance to manage risks for one low price. Results are typically available in three to four weeks.

Contact us to get started!