Thermography New system enhances laser plastic welding with real-time thermal insights

Related Vendors

LPKF WeldingQuipment GmbH

LPKF Laser & Electronics AG

HASCO Hasenclever GmbH + Co KG

Jongen Werkzeugtechnik GmbH

AMPCO METAL Deutschland GbmH

With Thermopro, LPKF brings a new level of process transparency to laser plastic welding: the inline thermographic system analyses temperature data immediately after welding, providing over 20 quality parameters for non-destructive inspection. The result: optimised strength, traceability, and reliable quality — even when using recycled plastics or complex multi-cavity tools.

LPKF introduces Thermopro, a thermographic analysis system specifically developed for laser plastic welding that transforms thermal data into concrete actionable insights. Through automated capture, evaluation and interpretation of surface temperature patterns immediately after welding, the system provides high process transparency that correlates with product joining quality and long-term product stability. Thermopro data enables welding process optimization to enhance component strength and long-term stability in a new dimension — completely non-destructively.

The system is designed for easy integration into existing production lines as a retrofit solution or as part of any new installation from the LPKF laser plastic welding product portfolio. Since thermographic analysis takes place directly after the welding process, usually cycle-time neutral, Thermopro saves valuable space and time. Depending on the process, this inline approach can replace conventional quality control stations or reduce testing intervals for cost-intensive additional inspections, thus keeping production flow efficient – including full process transparency and traceability to every product ID.

Developed in collaboration with experts specifically from the field of Automatic Optical Inspection (AOI), the system converts complex thermal data into more than 20 different quality parameters. This comprehensive analysis enables users to:

• Identify components that pass initial leak tests but would fail during temperature cycling tests

• Optimize processes for improved strength and reduced cycle times

• Monitor material property or process variations in real-time

• Achieve secure traceability with thermal data linked to each component ID

• Benefits for markets with high quality requirements

For medical device manufacturers, the Thermopro system provides the foundation for regulatory compliance, essential documentation requirements and traceability while ensuring the long-term integrity of, for example, fluid-carrying components and sensitive enclosures. The ability to detect subtle thermal anomalies is particularly important for components with zero-defect tolerance.

Automotive suppliers benefit from Thermopro’s ability to monitor production variations in multi-cavity tools, ensuring consistent quality in high-volume production. As the industry increasingly incorporates recycled materials and flame retardants into plastic components, the system's ability to detect and compensate for varying material properties becomes crucial for maintaining quality standards while meeting sustainability goals.

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