Laser Welding
Laser Welding Services for Medical and High-Tech Industries
Laser welding uses a focused, high-energy beam of light to fuse metal parts at a localized joint, producing a weld with a narrow heat-affected zone and high depth-to-width ratio relative to conventional fusion welding processes. These characteristics make laser welding well suited to small and micro-scale metal assemblies where thermal distortion, dimensional change, or metallurgical damage to surrounding material would compromise part function. Brunk performs laser welding on Trumpf systems, the same platform used for laser cutting operations, which allows both processes to be managed under a single equipment qualification and quality framework.
Process Characteristics
In laser welding, beam energy is delivered in a highly concentrated spot, typically between 0.1 and 0.6 mm in diameter at the focal point, depending on the application. The rapid energy delivery and small spot size produce a narrow, deep weld profile with limited thermal spread into the surrounding base material. The heat-affected zone in a laser weld is substantially smaller than in TIG or resistance welding, which is significant for components made from alloys whose properties are sensitive to thermal cycling. For nitinol, titanium, and austenitic stainless steel components used in medical devices, maintaining the base material’s mechanical and corrosion properties in the area adjacent to the weld joint is a design and process requirement that laser welding is specifically capable of meeting.
Weld quality is governed by beam parameters including power, pulse duration, pulse frequency, and focal position, as well as joint fit-up, fixturing, and shielding gas coverage. At Brunk, weld parameters are developed and qualified against defined acceptance criteria for each application. Process parameter records are maintained for each production run, and weld joints are inspected per the applicable acceptance standard.
Applications in Medical Device and High-Tech Manufacturing
Laser welding at Brunk is used most frequently for small-scale assemblies in medical device programs, including cardiovascular components, implantable device housings, surgical instrument assemblies, and drug delivery device components. These applications typically involve thin-wall geometries, tight dimensional requirements at the weld joint, and materials such as stainless steel, titanium, and nitinol that require careful thermal management during joining.
In high-tech manufacturing programs, laser welding is used for hermetic sealing of small enclosures, joining of dissimilar metals where the weld geometry and heat input requirements are not compatible with conventional fusion welding, and assembly of components with features that are inaccessible to resistance or TIG welding processes.
Quality and Inspection
Weld inspection at Brunk is performed using visual examination and, where required by the application, cross-sectional metallographic analysis to verify penetration depth, weld width, and the absence of porosity or cracking. Dimensional inspection of welded assemblies is performed on CMM or optical measurement systems to confirm that weld shrinkage and thermal distortion have not caused the assembly to go out of tolerance. For hermetic applications, leak testing is performed per the applicable test method. All inspection results are documented to the program record and are available to support design history file requirements for ISO 13485 regulated programs.
Request Laser Welding for Your Assembly
Submit your assembly drawings to discuss joint configuration, material, and inspection requirements for laser welding at Brunk.
Frequently Asked Questions
What is laser welding and how is it used in the medical industry?
Laser welding uses high-energy light to fuse metals with minimal heat spread, producing clean, precise joints. In the medical industry, it assembles surgical instruments, catheter components, implantable device housings, and micro-assemblies requiring biocompatibility and hermeticity. Brunk specializes in welding medical devices with validated, repeatable processes.
What are the advantages of laser welding in high-tech applications?
Key advantages include micro-scale precision, small HAZ for dimensional stability, reliable hermetic seals, compatibility with sensitive electronics, and seamless automation for consistent, high-throughput production. These advantages of laser welding are central to Brunk’s approach to laser welding for medical and high tech industry needs.
What materials can be laser welded for medical devices?
Common options are 316L stainless steel, titanium, nickel-based alloys, cobalt-chromium, and precious metals like platinum. With appropriate process tuning, certain aluminum and copper alloys can also be welded. Brunk’s medical welding expertise ensures the right parameters for each application.
Which industries benefit most from laser welding technology?
Medical devices, microelectronics, aerospace and defense, telecom hardware, precision instrumentation, and automotive laser welding benefit most— particularly where clean, traceable, and dimensionally stable welds are required. Brunk supports these sectors with validated laser welding benefits tailored to their needs.
