Skip to main navigationSkip to main contentSkip to footer
FFTlasertec

Laser technology

Laser technology at the highest level

Laser technology has established itself as one of the most innovative and efficient methods in modern manufacturing. It is versatile and has a number of advantages over conventional machining processes. Particularly noteworthy are the high production quality and process speed as well as the low heat input into the workpiece. The laser works without contact, making it very low-maintenance and environmentally friendly. This is reflected in the high availability and sustainable footprint of our laser systems.
For all these areas of application, the FFTlasertec Laser Protection Cabin provides a safe enclosure for all these applications.

Maximum precision and flexibility for your production

The demands on modern manufacturing processes are constantly increasing: components must be manufactured with ever greater precision, while at the same time production times must be optimized and costs reduced. This is exactly where laser technology comes into play: innovative laser systems for joining, cutting and processing components - tailored to your production. We will find an efficient and automated solution for your production.

FFTlasertec
FFTlasertec
FFTlasertec
FFTlasertec Laser Protection Cabine

Processing method

The areas of application for lasers are very diverse. From fully automated production systems to prototype production in our in-house laboratory, we are the right partner for laser material processing.

Welding

Laser beam welding

In laser beam welding, one or more workpieces are joined together inseparably and with a material bond. A major advantage of laser-welded components is the concentrated energy input into the workpiece. Among other things, this leads to less thermally induced distortion. A special feature of laser welding is that all seam geometries (butt, overlap or fillet welds) can be produced. The weld seam is produced without contact by a relative movement between the workpiece and the laser beam. Both the component and the processing optics can be moved.

Remote scanner welding

If galvanometer mirrors or prisms are installed in the optics, which can freely position the laser beam on a processing surface, this is referred to as scanner optics. A relative movement between the optics and the workpiece during the welding process is not necessary. If the scanner optics or the component is moved in combination with the mirrors, this is referred to as an on-the-fly process.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Non-contact
  • Seam tracking

Soldering & welding with filler material

Tactile laser processes

The tactile laser processes with filler material are subdivided into welding and soldering. In contrast to remote laser welding, the processing optics touch the workpiece with the wire, which simultaneously creates a seam. The laser beam melts the wire during the machining process so that the material properties at the joint can be specifically influenced and gaps can be bridged. Special spot geometries are also used in certain areas of application, allowing the melt pool to be specifically influenced. In addition, existing zinc can be dissolved and removed with the help of pre-spots, which can effectively prevent connection errors in the soldered seam.

Difference between soldering and welding:

Soldering: The filler material has a lower melting point than the material of the workpiece (one s less), which means that only the wire and not the component itself is melted by the effect of the laser beam. Due to the low heat input, the component remains dimensionally stable and excellent seam surfaces can be produced.

Welding: The wire has a similar melting point to the workpiece (one s less), so that both the wire and the component are melted and joined together during the process. The strength of welded joints is significantly higher than that of soldered joints.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Tactile seam tracking
  • Bridging of larger joining gaps
  • Optically high-quality seam

Cutting

Laser cutting

There are three different laser cutting processes: Flame cutting, fusion cutting and sublimation cutting.

In the first of these processes, the processing optics are guided very close to the surface of the workpiece, while specific gases are fed in to optimize the cutting process. In flame cutting, oxygen is used to promote an exothermic reaction and enable rapid separation of the material. In fusion cutting, for example, nitrogen is used to expel the molten material from the cut, leaving a precise, clean edge.

The latest technology in laser cutting is based on the principle of sublimation. In this process, a pulsed laser beam is repeatedly and very quickly guided along a cutting geometry by scanner optics. A small amount of material is vaporized by each pulse, so that almost no heat is introduced into the component. As a result, the surrounding material, such as paint, remains intact and is not detached or melted. This results in a clean cut edge, distortion is avoided and surface damage is prevented so that corrosion, for example, cannot occur.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High cutting quality (precise, smooth, burr-free and rework-free)
  • High process speed
  • Very good automation capability
  • Almost all materials can be cut
  • Non-contact
  • Remote cutting process possible without process gas

Cleaning & structuring

Laser cleaning

Laser cleaning is increasingly being used in areas such as decoating, paint stripping and cleaning. An (ultra) short pulse laser is used to specifically loosen the dirt or unwanted coating from the material and remove it via a process extraction system. The base material remains intact - it is neither removed nor damaged. However, due to the low heat input, it may be necessary to repeat the process several times in order to achieve optimum results.

A particularly common area of application for laser cleaning can be found in electromobility, especially in the manufacture of batteries. Here, a cathodic dip coating is applied to the battery cover, which serves as a protective layer. However, this layer can affect the necessary conductive connection between the battery cover and the battery box. Through the targeted use of the laser, the paint is precisely removed from the affected areas so that the desired conductive connection is restored.

Advantages

  • Base material is neither removed nor damaged
  • High precision
  • Environmentally friendly and dry
  • Minimal heat input
  • High process speed
  • Very good automation capability
  • Non-contact
  • Rework-free

Laser structuring

Laser structuring is used to optimally prepare adhesive and other functional surfaces. The material is structured in a targeted manner using an (ultra) short pulse laser. A structured surface is particularly important in adhesive technology. On the one hand, the adhesive bead can slip on a smooth surface and, on the other hand, the targeted geometric structuring can significantly increase the adhesive strength, as the adhesive adheres better to rough and cleaned surfaces. This process can be used to sustainably increase corrosion resistance.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

Hybrid

Laser hybrid welding

Laser hybrid welding combines the advantages of laser welding and gas metal arc welding (GMAW) to create a highly efficient welding process.

Gas metal arc welding (GMAW ) is an arc welding process in which an endless wire electrode melts under a shielding gas cover. The gas protects against the influence of the surrounding atmosphere. The MSG process is a tactile welding process in which the wire is inserted into the workpiece. The electric current flowing through the wire causes it to melt.

The laser supports this process by also focusing high-energy light onto the workpiece, causing the molten pool to penetrate deep into the material and create an even stronger bond. The combination of both processes enables a particularly precise and deep weld seam, which ensures greater strength and better quality.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

Laser beam welding

In laser beam welding, one or more workpieces are joined together inseparably and with a material bond. A major advantage of laser-welded components is the concentrated energy input into the workpiece. Among other things, this leads to less thermally induced distortion. A special feature of laser welding is that all seam geometries (butt, overlap or fillet welds) can be produced. The weld seam is produced without contact by a relative movement between the workpiece and the laser beam. Both the component and the processing optics can be moved.

Remote scanner welding

If galvanometer mirrors or prisms are installed in the optics, which can freely position the laser beam on a processing surface, this is referred to as scanner optics. A relative movement between the optics and the workpiece during the welding process is not necessary. If the scanner optics or the component is moved in combination with the mirrors, this is referred to as an on-the-fly process.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Non-contact
  • Seam tracking

Tactile laser processes

The tactile laser processes with filler material are subdivided into welding and soldering. In contrast to remote laser welding, the processing optics touch the workpiece with the wire, which simultaneously creates a seam. The laser beam melts the wire during the machining process so that the material properties at the joint can be specifically influenced and gaps can be bridged. Special spot geometries are also used in certain areas of application, allowing the melt pool to be specifically influenced. In addition, existing zinc can be dissolved and removed with the help of pre-spots, which can effectively prevent connection errors in the soldered seam.

Difference between soldering and welding:

Soldering: The filler material has a lower melting point than the material of the workpiece (one s less), which means that only the wire and not the component itself is melted by the effect of the laser beam. Due to the low heat input, the component remains dimensionally stable and excellent seam surfaces can be produced.

Welding: The wire has a similar melting point to the workpiece (one s less), so that both the wire and the component are melted and joined together during the process. The strength of welded joints is significantly higher than that of soldered joints.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Tactile seam tracking
  • Bridging of larger joining gaps
  • Optically high-quality seam

Laser cutting

There are three different laser cutting processes: Flame cutting, fusion cutting and sublimation cutting.

In the first of these processes, the processing optics are guided very close to the surface of the workpiece, while specific gases are fed in to optimize the cutting process. In flame cutting, oxygen is used to promote an exothermic reaction and enable rapid separation of the material. In fusion cutting, for example, nitrogen is used to expel the molten material from the cut, leaving a precise, clean edge.

The latest technology in laser cutting is based on the principle of sublimation. In this process, a pulsed laser beam is repeatedly and very quickly guided along a cutting geometry by scanner optics. A small amount of material is vaporized by each pulse, so that almost no heat is introduced into the component. As a result, the surrounding material, such as paint, remains intact and is not detached or melted. This results in a clean cut edge, distortion is avoided and surface damage is prevented so that corrosion, for example, cannot occur.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High cutting quality (precise, smooth, burr-free and rework-free)
  • High process speed
  • Very good automation capability
  • Almost all materials can be cut
  • Non-contact
  • Remote cutting process possible without process gas

Laser cleaning

Laser cleaning is increasingly being used in areas such as decoating, paint stripping and cleaning. An (ultra) short pulse laser is used to specifically loosen the dirt or unwanted coating from the material and remove it via a process extraction system. The base material remains intact - it is neither removed nor damaged. However, due to the low heat input, it may be necessary to repeat the process several times in order to achieve optimum results.

A particularly common area of application for laser cleaning can be found in electromobility, especially in the manufacture of batteries. Here, a cathodic dip coating is applied to the battery cover, which serves as a protective layer. However, this layer can affect the necessary conductive connection between the battery cover and the battery box. Through the targeted use of the laser, the paint is precisely removed from the affected areas so that the desired conductive connection is restored.

Advantages

  • Base material is neither removed nor damaged
  • High precision
  • Environmentally friendly and dry
  • Minimal heat input
  • High process speed
  • Very good automation capability
  • Non-contact
  • Rework-free

Laser structuring

Laser structuring is used to optimally prepare adhesive and other functional surfaces. The material is structured in a targeted manner using an (ultra) short pulse laser. A structured surface is particularly important in adhesive technology. On the one hand, the adhesive bead can slip on a smooth surface and, on the other hand, the targeted geometric structuring can significantly increase the adhesive strength, as the adhesive adheres better to rough and cleaned surfaces. This process can be used to sustainably increase corrosion resistance.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

Laser hybrid welding

Laser hybrid welding combines the advantages of laser welding and gas metal arc welding (GMAW) to create a highly efficient welding process.

Gas metal arc welding (GMAW ) is an arc welding process in which an endless wire electrode melts under a shielding gas cover. The gas protects against the influence of the surrounding atmosphere. The MSG process is a tactile welding process in which the wire is inserted into the workpiece. The electric current flowing through the wire causes it to melt.

The laser supports this process by also focusing high-energy light onto the workpiece, causing the molten pool to penetrate deep into the material and create an even stronger bond. The combination of both processes enables a particularly precise and deep weld seam, which ensures greater strength and better quality.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

Laser beam welding

In laser beam welding, one or more workpieces are joined together inseparably and with a material bond. A major advantage of laser-welded components is the concentrated energy input into the workpiece. Among other things, this leads to less thermally induced distortion. A special feature of laser welding is that all seam geometries (butt, overlap or fillet welds) can be produced. The weld seam is produced without contact by a relative movement between the workpiece and the laser beam. Both the component and the processing optics can be moved.

Remote scanner welding

If galvanometer mirrors or prisms are installed in the optics, which can freely position the laser beam on a processing surface, this is referred to as scanner optics. A relative movement between the optics and the workpiece during the welding process is not necessary. If the scanner optics or the component is moved in combination with the mirrors, this is referred to as an on-the-fly process.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Non-contact
  • Seam tracking

Tactile laser processes

The tactile laser processes with filler material are subdivided into welding and soldering. In contrast to remote laser welding, the processing optics touch the workpiece with the wire, which simultaneously creates a seam. The laser beam melts the wire during the machining process so that the material properties at the joint can be specifically influenced and gaps can be bridged. Special spot geometries are also used in certain areas of application, allowing the melt pool to be specifically influenced. In addition, existing zinc can be dissolved and removed with the help of pre-spots, which can effectively prevent connection errors in the soldered seam.

Difference between soldering and welding:

Soldering: The filler material has a lower melting point than the material of the workpiece (one s less), which means that only the wire and not the component itself is melted by the effect of the laser beam. Due to the low heat input, the component remains dimensionally stable and excellent seam surfaces can be produced.

Welding: The wire has a similar melting point to the workpiece (one s less), so that both the wire and the component are melted and joined together during the process. The strength of welded joints is significantly higher than that of soldered joints.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High seam quality (precision, strength, tightness, surface etc.)
  • High process speed
  • Very good automation capability
  • Wide range of materials can be welded
  • Tactile seam tracking
  • Bridging of larger joining gaps
  • Optically high-quality seam

Laser cutting

There are three different laser cutting processes: Flame cutting, fusion cutting and sublimation cutting.

In the first of these processes, the processing optics are guided very close to the surface of the workpiece, while specific gases are fed in to optimize the cutting process. In flame cutting, oxygen is used to promote an exothermic reaction and enable rapid separation of the material. In fusion cutting, for example, nitrogen is used to expel the molten material from the cut, leaving a precise, clean edge.

The latest technology in laser cutting is based on the principle of sublimation. In this process, a pulsed laser beam is repeatedly and very quickly guided along a cutting geometry by scanner optics. A small amount of material is vaporized by each pulse, so that almost no heat is introduced into the component. As a result, the surrounding material, such as paint, remains intact and is not detached or melted. This results in a clean cut edge, distortion is avoided and surface damage is prevented so that corrosion, for example, cannot occur.

Advantages

  • Minimal heat input
  • High aspect ratio
  • High cutting quality (precise, smooth, burr-free and rework-free)
  • High process speed
  • Very good automation capability
  • Almost all materials can be cut
  • Non-contact
  • Remote cutting process possible without process gas

Laser cleaning

Laser cleaning is increasingly being used in areas such as decoating, paint stripping and cleaning. An (ultra) short pulse laser is used to specifically loosen the dirt or unwanted coating from the material and remove it via a process extraction system. The base material remains intact - it is neither removed nor damaged. However, due to the low heat input, it may be necessary to repeat the process several times in order to achieve optimum results.

A particularly common area of application for laser cleaning can be found in electromobility, especially in the manufacture of batteries. Here, a cathodic dip coating is applied to the battery cover, which serves as a protective layer. However, this layer can affect the necessary conductive connection between the battery cover and the battery box. Through the targeted use of the laser, the paint is precisely removed from the affected areas so that the desired conductive connection is restored.

Advantages

  • Base material is neither removed nor damaged
  • High precision
  • Environmentally friendly and dry
  • Minimal heat input
  • High process speed
  • Very good automation capability
  • Non-contact
  • Rework-free

Laser structuring

Laser structuring is used to optimally prepare adhesive and other functional surfaces. The material is structured in a targeted manner using an (ultra) short pulse laser. A structured surface is particularly important in adhesive technology. On the one hand, the adhesive bead can slip on a smooth surface and, on the other hand, the targeted geometric structuring can significantly increase the adhesive strength, as the adhesive adheres better to rough and cleaned surfaces. This process can be used to sustainably increase corrosion resistance.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

Laser hybrid welding

Laser hybrid welding combines the advantages of laser welding and gas metal arc welding (GMAW) to create a highly efficient welding process.

Gas metal arc welding (GMAW ) is an arc welding process in which an endless wire electrode melts under a shielding gas cover. The gas protects against the influence of the surrounding atmosphere. The MSG process is a tactile welding process in which the wire is inserted into the workpiece. The electric current flowing through the wire causes it to melt.

The laser supports this process by also focusing high-energy light onto the workpiece, causing the molten pool to penetrate deep into the material and create an even stronger bond. The combination of both processes enables a particularly precise and deep weld seam, which ensures greater strength and better quality.

Advantages

  • Creation of surface geometries with specifically modified technical properties
    • Friction properties
    • Surface size
    • Electrical & thermal friction properties
  • High precision & process speed
  • Environmentally friendly and dry
  • Minimal heat input
  • Very good automation capability
  • Non-contact & rework-free

More than 600 laser systems realised in over 25 years Our references

We have been developing and installing laser systems worldwide since 1998. Our innovative solutions are not only highly regarded by renowned automotive brands such as BMW, Ford, VW, Mercedes, Porsche, GM and Audi, but also by newcomers such as Vinfast and Ceer. These long-standing partnerships are testament to the high quality and reliability of our systems. We also supply customized laser systems outside the automotive industry, for example in the "white goods" sector to Electrolux, Miele, Winterhalter etc.

0
Welding
0
Brazing
0
Cutting
0
Ceaning

With over 600 realized systems, we have acquired extensive expertise in the application of laser technologies in the fields of welding, soldering, cutting, cleaning and hybrid processes. Every system we develop helps to optimize our customers' manufacturing processes and ensure maximum precision and efficiency. We are proud to play a key role in modern industrial production and to constantly set new standards in laser technology.

FFTlasertec Diagram
A man wearing a white coat is sitting in front of two screens in an office (laboratory)

Tests, research and process development Large technology lab

Our technology laboratory is an innovative center for tomorrow's solutions. This is where we develop and test state-of-the-art technologies, including lasers, image processing, resistance spot welding, hemming and lightweight construction technologies. With first-class equipment and many individual test cells, we guarantee the highest quality and precision. Our laboratory also offers extensive facilities for prototyping and developing customized solutions to meet our customers' specific requirements. We bring ideas to life and support you in testing your visions and bringing them into a production-ready manufacturing process.

The technology of tomorrow is being created here Examples of technological developments

Pioneering innovations are created in our technology lab: from AI-supported analysis tools and smart process monitoring to sustainable energy systems and new laser processes. We are driving automation forward with cutting-edge research and prototypes.

Battery trays

OCT for seam tracking and quality monitoring

The system monitors laser welding in real time: it detects edges, seams, component position and geometry, corrects the beam position, measures the welding depth, records process fluctuations and checks the seam for defects and disruptive factors after welding.

The picture shows an electric vehicle whose battery and wheels are clearly recognizable.

Processes for battery trays

In preparation for the welding process, the battery base is first structured to create the optimum conditions for the connection. Either the tactile or laser hybrid welding process is then used to ensure precise and stable weld seams.

Another process is the paint stripping of the battery floor cover to ensure potential equalization between the cover and housing. This prevents dangerous current differences and ensures that no harmful voltages occur in the event of a short circuit or electrical fault.

A metal plate with several holes evenly distributed over the surface.

Bipolar plate laser welding

Bipolar plates made of ≤100 µm stainless steel are welded at >500 mm/s using remote scanner welding. High tightness requirements are placed on the welding process and hermetic weld seams are required. Due to the low material thickness, a highly complex and precise clamping device is required to create a zero gap. In addition, attention must be paid to cleanliness, heat input, the laser equipment used, the shielding gas and many other factors.

Laser technology that inspires. We look forward to getting in touch with you:

Send us your concept idea, your automation requirements or a description of your laser process that we can support you with. We look forward to presenting our standardized portfolio to you, but also to developing new solutions together with you.

Your FFTlasertec contact:

Request - lasertec

Contact details

* Mandatory field

Please wait