Custom laser welding: From standard system to customer-specific solution

This is exactly where ALPHA LASER’s approach to custom laser welding comes in. Adaptations are not developed independently of existing machine concepts, but are based on standard systems whose core functions are retained and specifically expanded. This enables the necessary flexibility without compromising the stability and reliability of a proven system. Mechanics, electronics, software and optics can be individually adapted. At the same time, the ALPHA LASER system architecture WINLaser 5, as a control and software platform, provides additional flexibility, as further I/Os can be integrated on the customer side.

From requirements to implementation in custom laser welding

The process of custom laser welding always begins with a precise understanding of the customer’s requirements. This involves not only assessing technical feasibility, but also estimating the expected effort. To ensure a reliable evaluation, sales and engineering must work closely together. This is the only way to assess at an early stage which adaptations are meaningful, feasible and economically viable.

In the next step, the required modifications are broken down transparently. The customer is given a clear overview of the effort involved in each individual adaptation package and the theoretical costs associated with them. This cost-benefit analysis is a key element, as it enables well-informed decisions regarding the scope and depth of customization.

In many cases, however, a purely theoretical evaluation is not sufficient. Before placing an order, customers often want to ensure that the planned custom laser welding approach will work in practice. For this purpose, a test setup can be created that replicates the future machine’s functionality as realistically as possible. This allows new functions and concepts to be practically validated in advance.

During such a feasibility study in custom laser welding, additional points often emerge that should be optimized or further developed. These are again evaluated in terms of effort, benefit and cost, and then discussed together with the customer. Once the final requirements have been defined and an order has been placed, implementation begins by the development engineers.

Practical example: customer-specific extension of an AL-Q

An example of this approach in custom laser welding is a customer project based on an AL-Q. As a standard system, the AL-Q is already a suitable machine for many applications: a laser process head in a closed working chamber, designed as a stationary system with appropriate size and space requirements. In this specific case, however, certain functionalities required for the customer’s application were missing.

The customer’s idea was to weld fillet welds simultaneously from both sides in order to counteract thermal distortion during welding. Based on this requirement, it was determined that the system needed to be extended by several components. Two process heads, two laser sources, two cameras and two gas supplies were defined. In addition, adjustable optics angles and a linear adjustment were implemented.

On this basis, ALPHA LASER developed a test concept and planned a corresponding test setup. Within this setup, the mechanical and optical adaptations were functionally implemented in order to verify feasibility under realistic conditions. After a successful feasibility study, the required functionality of the final machine was reviewed again and supplemented with additional aspects.

This step clearly shows how customer-specific solutions in custom laser welding are developed in practice: not all requirements are fully defined from the outset. Some requirements only arise during the use of the test setup. In this case, for example, the requirement to display and lock the angular position was added.

Once the customer-specific requirements had been fully clarified, the final adaptation package could be defined based on the effort estimation. In addition to the mechanical modifications and additional optical components, further functions were also integrated on the software side.

Proven foundation, targeted customization

The example shows that custom laser welding does not start from scratch. The key is rather to adapt a proven standard platform in such a way that it meets the specific requirements of the customer. The core functions are retained, while targeted extensions in mechanics, electronics, software and optics enable the necessary level of customization.

This results in a custom solution built on a solid foundation: flexible in design, transparent in evaluation and reliable in implementation.