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Ultra-fast laser micromachining - what’s all the fuss about?

Table 1

Ultra-fast laser micromachining has been getting a lot of press lately; does it live up to its billing? In my view, ultra-fast micromachining has terrific potential, but I’d like to temper the enthusiasm with a little dose of reality. Miyachi America has a new micromachining applications laboratory set up with a variety of different ultra-fast laser micromachining sources and motion platforms, so I am in a perfect position to show some examples of what ultra-fast laser micromachining can do from a laser independent systems integrator perspective

Micro TIG Welding: what is it and what can you do with it?

Micro TIG welding automotive applications

Miyachi America is best known for its resistance and laser welding technologies. To complement these well-established processes, Micro TIG welding was recently added to our product line. The Micro TIG process expands our process offering, particularly for materials such as copper. This blog veers away from our normal, application specific format to provide a quick introduction to the Micro TIG process:

Scan heads for micro laser welding: “Ham n’ Eggs” of laser industry

galvo welded disk drive armatures

What do you get when you pair a non-contact, high intensity heat source with a compact, relatively inexpensive high speed motion system?  A perfect match!  The "ham n' eggs" of laser industry: a micro laser welding system that can push productivity to the max with three key features:

Why weld monitoring? 3 Reasons: Analysis – Stability - Yield

Weld monitor main screen

Resistance spot welding monitors and checkers measure the electrical and mechanical aspects of the welding process; they analyze weld quality enabling the user to make adjustments and improvements resulting in process stability, and, ultimately, improved yields.  Here’s a quick look at the three most important reasons to consider adding a weld monitor or weld checker to your resistance welding line:

Tube cutting with a femtosecond disk laser - ROI in less than a year

tube cutting with a femtosecond disk laser

Microsecond fiber and pulsed Nd:YAG lasers have been used successfully for hypo tube and stent cutting for many years. The only downside is that cut parts often require a number of post processing operations, depending on material and part requirements.  These additional manufacturing steps can add significant cost; they also add to the handling logistics burden for what, in many cases, are mechanically delicate parts, not to mention the added problem of having to deal with chemical-based processes and the disposal of hazardous waste.

Battery pack welding: which technology for your job?

benefits of battery welding technologies

"Ugh - my battery just died!" "Can I use your charger?" "Mind if I recharge my phone?"  Batteries are everywhere, and we've become increasingly dependent on them in many aspects of our daily lives: portable electronic devices, cordless power tools, energy storage, and hybrid and EV cars. Thus, the demand to manufacture batteries that meet or exceed quality and production requirements for these products, is great.

Resistance spot welding, micro TIG welding, and laser welding processes all enable high quality volume production.  The selection of one technology over another is usually made based on the application's specific requirements and the alignment of the technology to these needs.

So, what battery welding technologies are available and what are the benefits of each?

Bringing Laser Technology In-House: 6 Simple Steps to Success!


Once the commercial justification for bringing laser technology in house is complete, new to laser manufacturers may still have some technical concerns.  We’ve recently worked on several very successful collaborations with first-time to laser manufacturers to turn their mountains into mole hills.  Now each system is on the floor in production and everyone is wondering what all the fuss was about.

4 Tips for Maximizing your 2D Data Matrix™ Code Readability


2D Data Matrix TM codes are made up of two parts: the finder pattern that tells the reader the code orientation and array size, and the actual encoded data. If you’re getting no read or a marginal read, you may have an issue with one these read factors.  It’s also worth noting that the quality (and price) of the reader can have a significant effect – particularly on small codes, and codes marked on shiny surfaces.

Resistance welding trouble shooting: 7 simple steps


You've been successfully running the same resistance spot welding program for days - months - years when all of a sudden it stopped working.  What do you do?  Where should you start?  When troubleshooting a problem with your resistance welding process, we've learned that it's best to start with the materials and move back toward the power supply.  Troubleshoot using 7 simple steps, in this order:

  1. Check the materials that are being welded.  See if your supplier is using the same base materials, plating, process, etc..  If a new lot of materials is causing problems, look for some parts from a previous lot to see if they will still weld normally.
  2. Check the electrodes.  Make sure the material, size and shape of the electrodes has not changed.  Also look at the electrode condition and resurfacing procedure.
  3. Check the tooling that holds the parts in position.  Make sure it has not been modified or damaged and that it holds the parts in the proper position.
  4. Check the weld head.  Inspect the electrode holders to make sure they are clamping the electrodes correctly.  Check the weld head motion and look for friction that might cause problems with follow-up. Check all of the electrical connections from the electrode holders, flexures, power bars, and weld cables to the power supply output terminals.  Check the mounting location of the Voltage Sense cables and make sure they are screwed down tight.
  5. Check the power supply.  Make sure it is connected to the correct line voltage.  Make sure all of the electrical connectors are secure.  Make sure it is operating properly and not giving any alarms.
  6. Verify all of the process settings including the power supply schedule, menu settings and weld head force and speed settings.
  7. Check with the operators to see if they are doing anything differently including electrode maintenance, part handling, initiation procedure.  If new operators are using the equipment, make sure they have been properly trained on footswitch operation, etc.

If you complete this troubleshooting list and are unable to identify the problem, you may want to conduct a process audit, in which case you'll find this Process Audit Worksheet helpful.  It can be used to document your process and includes many details that you may not have considered as important, but could negatively affect your process if not controlled.  If, after conducting a process audit you STILL can't identify the problem, feel free to contact us - our application engineers would be happy to assist.


How to Minimize Cycle Time for Large Area Laser Marking

laser marked logo

Most industrial laser marking applications are small and precise. But every now and then, an application comes along requiring a large area mark – with fill - and that generally means long process times, which no manufacturer likes to hear. Fortunately, there are several tricks of the trade that can greatly reduce process time, and, in some cases, the optimized process time can be significantly improved.

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