Rapid Prototyper Adds Laser Welding System, Establishes Weld Analysis Center

        Manufacturers and industries have seen the 'light'... powerful laser light and its potential for welding applications. For intricate shapes and patterns, thin, paper like materials, or high speed, deep penetration welding of thick plates, aluminum and other, previously hard-to-weld alloys, welding dissimilar materials or of different thickness. Also for producing precision seams-all with high strength joint integrity plus cost and production efficiency.

        Using the fine tuned welding capabilities of laser technologies, design and engineering teams have been reinventing parts that reduce product weights while increasing strength, have replaced multi-part components with fewer units, and have contained costs by being able to substitute with more economical materials. The possibilities seem endless and, now, one rapid prototype organization is providing advance assistance and research in turning the imagined into reality.

        3-Dimensional Services, Rochester Hills, Michigan, and its subsidiary, Urgent Design & Manufacturing, Lapeer, Michigan, have recently completed the acquisition and installation of a new, advanced laser welding system to complement their array of rapid prototype technologies. The system, along with the establishment of a new metallurgical analysis station where weld and material microstructures and physical properties can be thoroughly studied, exemplifies the companies' heightened focus on laser welding, plus customers' needs to have not only parts built but also to have processes developed and proven.

        The custom designed and built welding system features a 8kW Trumpf high frequency CO₂ laser while its 3-axis, bridge-type work station, laser and motion control unit and turnkey integration were provided by Futek. The flexibility of the system--with power to accomplish up to l5mm (.590") penetration high strength welds along with precision and beam quality to join thin materials with minimal distortion and limited heat affected zones--provides the two companies with the versatility to weld and assemble a wide variety of prototype and low production applications. To date, these applications include parts for fuel injection, transmissions, fuel cells, exhaust systems, pressure transducers and supplemental restraint systems.

        The motion system was designed for the specific demands of rotational welding, yet with agility to also do linear as well as contour welding. The variable output power control permits welding of dissimilar materials and those of varying thickness, making the weld station ideal for tailored blank welding for subsequent stamping and forming operations. The station has an ample 2' x 3' working envelope for larger pieces, or accommodates the simultaneous fixturing for multiple weld-type applications. The CNC unit, controlling both the laser's operating parameters and the motion system, makes changeover for prototype level volumes fast and easy.

        According to Mike Finta, director of engineering at 3-Dimensional Services, the new system has significantly increased the firms' ability to meet customers' needs. "We've always been able to fashion welded prototypes prior to getting this laser system," he says, "but now, the weld station allows us to reach a new level of concentration on the welding process. Now, we're better able to accurately duplicate the actual production environment...with equipment similar in power, speed and precision capabilities to what our clients will use in their plants. This in turn not only means we're providing prototype parts for successful product launches, but also, with our analysis capabilities and sampling procedures, we're giving customers reliable, predictable manufacturing data to make the transition and implementation into their production processes as smooth as possible."

        While the laser weld station is new to the two companies, laser technology applications are not. They have been using lasers, in power ranges of up to 3kW, for more than 10 years. These 2- and 3-axis lasers were designed and are predominantly used for cutting processes, though were frequently doing double duty for welding and assembly work.

        In addition to laser welding, 3-Dimensional Services, Urgent Design & Manufacturing, and a third sister company, Urgent Plastic Services--specialists in injection molding of plastic prototype parts--provide rapid prototyping (allowing for the completion of prototype parts up to 70% faster than traditional prototype technologies) for other manufacturing disciplines, including machining, mold and injection mold, cast, stamped and formed fabrications, hydroforming, high definition stamping (intricate shapes and maximum elongation) of super alloys, and assembly operations.

        For more information contact:
        3-Dimensional Services
        2547 Product Drive
        Rochester Hills, MI 48309
        248-852-1333
        Fax: 248-852-2110
        www.3dimensional.com