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Plastic welding with digital printing technology

Welding with digital printing technology

The high-precision laser welding process is increasingly being used today as an alternative to ultrasonic and high-frequency welding of plastics.

Plastic welding with digital printing technology
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Plastic welding

The process-reliable and economical application of a complex additive is a prerequisite. In the past, there was no industrially suitable solution for this. Together with partners, REA JET has developed a highly interesting digital printing process using REA JET Clearweld Primer for automation.

Classically transparent plastics such as PE, PP, PC, PS and SAN naturally only have a limited laser absorption capacity, which makes plastic welding impossible or very difficult. With the REA JET solution, transparent and laser-transparent plastic materials can be prepared with the REA JET Clearweld Primer, which has a high specific laser energy, so that they can be welded with lasers. Injection-molded plastic parts and nonwovens can also be welded with this solution.

At a glance

Examples of plastic welding

Medical consumables such as IV filters, connections, tube connectors, etc.
Medical consumables such as IV filters, connections, tube connectors, etc.
Vials that have to be welded due to their specific part geometry
Vials that have to be welded due to their specific part geometry
Excellent transparency of the welding area
Excellent transparency of the welding area
Excellent weld seam strength
Excellent weld seam strength
Disposable items for everyday use such as luggage tags
Disposable items for everyday use such as luggage tags
Components such as oil filters etc.
Components such as oil filters etc.

Process steps

Coating process

  • REA JET's range of activities
  • Using REA JET HR printing technology, transparent plastic parts are digitally printed economically and precisely with REA JET Clearweld Primer
  • The REA JET DOD 2.0 system is suitable for large areas
  • The primer is highly effective at absorbing specific laser energy
  • Automated digital printing of primer for reproducible, more cost-effective and better welding results
Coating process
Pre-assembly process

Pre-assembly process

  • The REA JET Clearweld Primer dries on the surface of the plastic part within a very short time
  • Positioning or pre-assembly of a second non-coated plastic part of the same material on the already coated plastic part in preparation for the welding process

Welding process

  • While both parts are pressed against each other, specific laser energy is directed into the interfaces between the parts
  • The laser beam passes through the upper part and the laser energy is absorbed in the welding area
  • This generates heat that melts the plastic and welds the parts together
  • After plasticization, the two parts are permanently joined together
Welding process
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Process advantages

The advantages of the REA JET Clearweld Primer solution

  • Very good optical weld seam quality
  • Very good strength of the weld seam
  • As the REA JET Clearweld Primer loses its color during the laser welding process, the weld seam typically appears colorless after welding.
  • No friction and no vibration during welding - particle-free welding process
  • Extreme flexibility in contouring the weld seam
  • Extremely high reproducibility, even and fine distribution of the primer over the contour
  • Very short drying time of the primer on the plastic surface
  • Suitability for automatic coating processes (high speed, linear movements, robot movements, etc.)
  • Reduced thermal stress on the plastic components during the welding process
  • Short welding time and high concentration of welding energy, especially for smooth plastic materials

Industrial solution

The complete
package from REA

Automation

REA JET Clearweld Primer Systems can be integrated into automated manufacturing processes.

Future-proof suitability

REA JET primers can be used for the entire range of plastic materials.

Process control

The contrast of the REA JET primers can be set very precisely and very reproducibly. The printer parameters are continuously monitored by the system and can be set online.

Efficiency

An optimum and uniform primer contrast can be achieved and maintained. This ensures optimum weldability and optimum efficiency of the process.

Partnership

The REA JET Clearweld Primer System is the innovative application profile solution for the plastics processing industry for digital printing of high-quality welding additives! REA offers the REA JET Clearweld Primer System, supports process integrators and takes over the installation and maintenance of the systems through its worldwide network of distributors.

REA has entered into an exclusive partnership with TechnoScriptum on the basis of digital printing with primers for plastic welding. Dr.-Ing. Rolf Klein of TechnoScriptum is a recognized consultant and expert in the plastics industry and in the field of laser welding processes in Germany and Europe.

The cooperation between REA and TechnoScriptum also includes the exclusive cooperation with the US company Crysta-Lyn, a supplier of specialty chemicals for the plastics industry and other industries.

These collaborations combine Crysta-Lyn's and TechnoSciptum's specific process know-how in laser welding with REA's installation and support expertise and a strong international distribution network.

The benefit for customers and integrators is a new, industry-standard turnkey solution.

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Germany

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