Laser Welding

Application-driven solutions designed for your assembly

How to Get Started with Laser Plastic Welding Webinar

Learn how to use laser plastic welding to achieve a precise, strong, and clean assembly.

How Configurable Laser Plastic Welding Can Save You Money

Learn how configuring a laser plastic welding machine to meet the needs of your of your unique application saves you time and money.

How to Design for Laser Plastic Welding Webinar

Learn how to design your parts for laser plastic welding.

Configurable, cost-effective laser plastic welding that meets your needs

Are you tired of trying to fit your plastic laser welding application into the constraints of one-size-fits-all laser welding machines? At Extol, we take a different approach. We design each laser welding solution around your application. That way, you get the optimum performance and cycle time for your needs.

The Laser Plastic Welding Process

Laser plastic welding uses a precise IR laser beam that is transmitted through a transmissive material and absorbed by an absorptive material. The two materials are held in tight contact with each other and the joint between them heats up and melts as energy from the laser is absorbed. The result is a clean weld with minimal flash.

Two parts clamped together


The two parts are clamped together with the IR transparent material on top and the absorbing material on the bottom.

Parts being heated together


The laser is transmitted through the top component and absorbed by the lower component, heating and melting the joint.

Parts being cooled after the heating process


The laser turns off and the clamping force is maintained to allow the joint to cool and solidify.

We’ve been doing IR for 20+ years.

Extol’s laser plastic welding solutions use infrared energy to melt and weld plastic. The IR energy used in laser welding is similar in many ways to the IR in Extol’s InfraStake technology. InfraStake uses broad-spectrum IR energy. This means that the IR emitting from an InfraStake bulb covers a range of wavelengths. In laser welding, the IR energy is a specific wavelength, not a range. And there are a handful of wavelengths used, from 600 to 2000 nm. Most often, a 980 nm wavelength is an optimal choice. We can also control the beam size, speed, power, and number of passes to optimize it for the application.
Chart of the Electromagnetic spectrum

Application-driven laser welding solutions

Many laser welding applications need a special solution to optimize speed and performance. We custom tailor each laser welding machine to the application. That means the machine can be as large or as small as you need it to be. It can apply force using whatever method you want. And it can use the laser technology that is best suited for your parts.

How Extol guides you to the best laser welding solution

COLLABORATE – We work with you to gain a deep understanding of the needs for your specific application.

DESIGN – We help you design your parts for the best results with laser welding. Not only do we provide laser welding guidelines to get you started, but we review your design and provide specific recommendations. Beyond that, we validate your design by welding and testing the assembly with equipment in our lab.

CONFIGURE – Using what we’ve learned about you and your application, we configure a solution that is perfect for your needs.

DELIVER – We design, build, and deliver your laser welding equipment. But we don’t stop there. Our exceptional team supports you from launch through the life of the program.

Laser Welding process animation

Laser Welding Benefits

Three yellow stars


Laser welding can minimize or eliminate unwanted particulate and visually unacceptable flash by precisely applying the right amount of energy to the weld surface. Excess heat isn’t needed to generate strong, clean, and repeatable welds.

clock moving fast


Extremely focused energy means the plastic is heated exceptionally fast. This translates to fast weld times.

Black target with red center


Miniaturized part designs and closer proximity of internal components is possible with the control and accuracy of Extol’s laser plastic welding system. The energy goes exactly where it needs to on every part.

Learn how to design for laser welding.

A properly designed weld joint is critical to achieving the desired weld strength and appearance. Follow our easy-to-use guidelines to optimize your part design for laser plastic welding and achieve the best weld possible.

Contour laser welding process


Contour laser welding uses one continuous pass of the laser along the weld path with enough energy to melt and weld the parts. This works well for flat to flat weld joints.

Quasi-Simultaneous laser welding process


Quasi-simultaneous laser welding uses many very fast passes along the weld path to simulate the laser energy being applied to the whole weld joint simultaneously. This works well in T-style weld joints to get consistent, simultaneous displacement in the weld joint.

Line beam laser welding process

Line Beam

Line beam laser welding uses optics to spread the laser energy into a curtain that is passed over the part like a wide paintbrush. This works well for small intricate parts and larger flat area welding.

Masking laser welding process


Masking uses a similar line beam curtain laser, but with a precision-cut mask over the part to shield the areas that don't require laser energy. This works well for ultra-precise welding with weld ribs less than 0.7 mm wide.

Find answers to all your questions about laser plastic welding.

What materials can be laser welded?

Most thermoplastic materials can be laser welded. The general rule of thumb is if they can be welded with another joining technology, they can be welded with laser. The two materials being welded together should be similar. Meaning, they should have the same chemical structure, overlapping melt temperatures, and their melt flow index should be of the same order.

How strong are laser welded parts?

Typically, laser welded parts are stronger than ultrasonic welding, and at least as strong as hot-plate and vibration welding.

Does the top part material have to be transparent to be laser welded?

Yes and no. The top part can look opaque, even black, to the human eye and still be able to be laser welded. It just needs to be transmissive at the correct IR wavelength. There are ways to color plastic parts that make them look opaque while still being transparent to IR energy.

Read our blog posts about laser welding.

Alternatives to Ultrasonic Welding

Alternatives to Ultrasonic Welding

If you’re familiar with plastic welding, you’ve probably encountered ultrasonic welding. It’s the most well-known plastic welding technology. But just because it’s popular, doesn’t mean it is the best choice for every application. It has many benefits, but also some drawbacks. What do you do if ultrasonic welding isn’t your best option? And how do you know?

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Introducing LaserLock™ Plastic Weld Tooling

Introducing LaserLock™ Plastic Weld Tooling

Have you seen laser plastic welding applications that are tricky to tool? How do you make sure the parts align properly every time? We have a solution for you! Introducing LaserLock™ plastic weld tooling.
Ensure consistent, strong welds with Extol’s patent-pending LaserLock™ plastic weld tooling. LaserLock tooling repeatably locates and holds your plastic parts inside the laser welding machine, which is crucial for success. This solution makes process setup easy and allows for more flexibility in your part design.

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Laser Plastic Welding Myths Debunked

Laser Plastic Welding Myths Debunked

There are several myths about laser plastic welding machines and their technology. Let us clear things up a bit. These are some of the top laser plastic welding myths DEBUNKED…

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Request a quote for a laser welder.

Tell us about your application and request a quote. Whether you want integrable laser components, a standalone machine, or custom automation, we’ve got you covered.

Let us know what you need.