When two plastics are clamped tightly together, a laser beam in the 1000nm range penetrates the upper layer and is absorbed by the lower layer which in turn is heated by the laser energy and transfers this heat to the upper layer resulting in both of the plastics melting and mixing to form a bond that is virtually as strong as the base material.

Initial investments for laser systems are typically higher, however, when the whole production chain and cost of ownership are taken into consideration, this assembly process results in significant savings, as operations and maintenance costs are significantly lower than of other assembly techniques.

It is highly recommended that designers and engineers reach out to an expert long before a design is frozen so they can receive proper guidance to design a laser-weldable joint and eliminate the potential for costly mistakes.