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Machines 2016, 4(3), 14; doi:10.3390/machines4030014

Open Source Laser Polymer Welding System: Design and Characterization of Linear Low-Density Polyethylene Multilayer Welds

1
Department of Materials Science and Engineering, Michigan Technological University, 601 M&M Building, 1400 Townsend Drive, Houghton, MI 49931-1295, USA
2
Smart and Small Thermal Systems Laboratory, Department of Mechanical Engineering, University of Maryland, College Park, MD 20742, USA
3
Department of Electrical & Computer Engineering, Michigan Technological University, Houghton, MI 49931, USA
*
Author to whom correspondence should be addressed.
Academic Editor: Xiaoliang Jin
Received: 26 May 2016 / Revised: 20 June 2016 / Accepted: 22 June 2016 / Published: 1 July 2016
(This article belongs to the Special Issue Precision Manufacturing Processes)
View Full-Text   |   Download PDF [8682 KB, uploaded 1 July 2016]   |  

Abstract

The use of lasers to weld polymer sheets provides a means of highly-adaptive and custom additive manufacturing for a wide array of industrial, medical, and end user/consumer applications. This paper provides an open source design for a laser polymer welding system, which can be fabricated with low-cost fused filament fabrication and off-the-shelf mechanical and electrical parts. The system is controlled with free and open source software and firmware. The operation of the machine is validated and the performance of the system is quantified for the mechanical properties (peak load) and weld width of linear low density polyethylene (LLDPE) lap welds manufactured with the system as a function of linear energy density. The results provide incident laser power and machine parameters that enable both dual (two layers) and multilayer (three layers while welding only two sheets) polymer welded systems. The application of these parameter sets provides users of the open source laser polymer welder with the fundamental requirements to produce mechanically stable LLDPE multi-layer welded products, such as heat exchangers. View Full-Text
Keywords: polymer welding; laser welding; polymer laser welding; additive manufacturing; open hardware; linear low density polyethylene; LLDPE; heat exchangers polymer welding; laser welding; polymer laser welding; additive manufacturing; open hardware; linear low density polyethylene; LLDPE; heat exchangers
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Laureto, J.J.; Dessiatoun, S.V.; Ohadi, M.M.; Pearce, J.M. Open Source Laser Polymer Welding System: Design and Characterization of Linear Low-Density Polyethylene Multilayer Welds. Machines 2016, 4, 14.

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