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Laser Solutions for the Automotive Industry
© 2014
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Our presenters
© 2014
Shane Stafford Creative Marketing Specialist
Dax Hamilton Laser Welding Sales Manager
Stephan Schmidt President
Mirela Orlowski Sales Engineer, Laser Depaneling
Rory Grondin Rapid Prototyping Sales Manager
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Questions
© 2014
@LPKF_USA
Mini Q&A after each guest speaker, one large Q&A to wrap up
4 © 2014
The Automotive Sector
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About LPKF
© 2014
Laser Plastic Welding Rapid PCB Prototyping
UV Laser Depaneling Laser Structuring of 3D MIDs
Hannover
Portland
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Laser Welding of Tail Lights
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How Does LPW Work?
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Joint Types
T Joint Lap Joint
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Benefits of Laser Plastic Welding
• Clean and precise
• Aesthetics
• Process monitoring
• Integration
• Short cycle times
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Plastics Compatibility
Common Automotive Plastics compatible with Laser Plastic Welding • Nylon materials (PA6, PA6/6, PA12) • POM • PBT • PC/ABS • PE
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Drivetrain and Fuel Components
Various sensor covers
Water level sensor (Black-black weld)
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CV boot or CV gaiter (Hard-soft weld)
Radial welded valve
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Drivetrain and Fuel Components
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Instrument Cluster Enclosure
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Questions?
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Laser Plastic Welding Applications
Drivetrain and Fuel System Components
Instrument Cluster
Enclosure
Tail Lights
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Laser Circuit Etching on Plastics
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What is an MID?
Circuit board Housing Connector Cable
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The Laser Direct Structuring Process
3. Metallization 1. Injection Molding 2. Laser Activation
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polymer + metal-organic complex Laser radiation
organic ligands
metal atom
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Laser Activation
Metal Nitrogen Oxygen
metal seeds
polymer + metallorganic complex
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The Laser Direct Structuring Process
3. Metallization 1. Injection Molding 2. Laser Activation
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Benefits of MIDs and LDS
MID Benefits
• Go from 2D to 3D • Fewer components/parts • Save space, reduce weight, lower
cost
LDS Benefits • Single-shot injection molding • Create complex 3D circuitry • High-resolution features • R&D through large scale production
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LDS Grade Materials
Common Automotive Plastics available in an LDS grade • Nylon materials (PA6, PA6/6, PA6/6T, PA12, PPA) • PC/ABS • LCP • PBT
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Wiring Harness
• Streamlined wiring
• Makes use of 3D design space
Before After
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Antennas
Photo courtesy of Molex
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Motorcycle Handlebar
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User Interface
Wiring Harness
GPS, Bluetooth, and Cell Antennas
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Laser Direct Structuring Applications
Motorcycle Handlebar
Questions?
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Stress-Free Processing of Optical Components
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Depaneling Populated PCBs
• UV laser depaneling of populated
PCBs
• Minimized debris - perfect for boards with sensitive optical components
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Debris-Free Laser Depaneling
Routing UV Laser
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UV Laser Depaneling
• No mechanical stress • Limited thermal stress • Cut any PCB material
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Limited Thermal Stress
125 µm polyimide (Kapton®)
• Cut on CO2 sytem w/ 20 µm beam • Charring results in 120 µm cut width
• Cut on UV system with 20 µm beam • Reduced HAZ results in 30 µm cut
width
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Flex Circuits in Cars
Rear Window Defrost
Under-Hood
Controls
Powertrain Controls
Fuel Pumps
Antilock Breaks
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Flex Circuits in Cars
Air Bag
Systems
GPS Systems
Starter/ Alternator
Electric Windows/
Seats
AC
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Questions?
© 2014
Flex Circuits in Cars
Mounted Back-Up Camera
Flex Cutting
34 © 2014
Rapid Prototyping of PCBs
• In-house mechanical milling or laser
processing
• Boards ready in under an hour
• Vital for reducing time-to-market
35 © 2014
Sub-Circuits for F1 Racing Teams
“Being able to test, verify, and modify sub-designs quickly while they are still in the design process gives our group the chance to focus on quality… No doubt, the LPKF system provides us with the leading edge on quality,
as well as stability and performance.”
36 © 2014
Prototyping Automotive Components
“The LPKF ProtoMat is small and easy to use. It is very useful to make all kinds of small-series PCBs. And it corresponds fast to design changes!”
- Tomokazu Wantanabe, DENSO
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• Rapid creation and fine tuning of RF
sensor boards
© 2014
RF Sensors
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Rapid Prototyping of PCBs
Mechanical Processing Mechanical/Laser Processing (combined)
Laser Processing
Applications: Test boards, sub-circuits
Applications: Test boards, sub-circuits, RF sensors
Applications: Test boards, sub-circuits, RF sensors
Materials: FR4, HF materials (Rogers)
Materials: FR4, HF materials (Rogers), fired ceramics
Materials: FR4, HF materials (Rogers), fired ceramics, flex
Min. trace/space: 4 mil/4 mil
Min. trace/space: 2 mil/1 mil
Min. trace/space: 2 mil/1 mil
Speed: Speed: Speed:
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Questions?
© 2014
Rapid Prototyping of PCBs
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Conclusion
Laser Solutions for the Automotive Industry • Laser plastic welding of lighting and
components
• Laser direct structuring of 3D MIDs
• Stress-free UV laser depaneling
• Rapid prototyping of PCBs
41 © 2014
Poll
Which technology interests you most? • Laser plastic welding • 3D circuitry on plastics • UV laser depaneling • Rapid PCB prototyping • None of them interest me :’(
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Thank you for your attention!
© 2014
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Contact Info
© 2014
Laser Plastic Welding Dax Hamilton
Laser Structuring of 3D MIDs Tim Heneveld
UV Laser Depaneling Mirela Orlowski
Rapid PCB Prototyping Rory Grondin
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Questions Submit via your GoToWebinar questions panel or Twitter (@LPKF_USA)
© 2014