A Medical Device Challenge: Welding Thin Wires Of Dissimilar Metals

Laser welding is crucial for joining delicate parts in medical devices. However, welding thin wires of materials like stainless steel, nitinol, or titanium presents challenges due to their difficult-to-weld properties. Coherent has developed a process to overcome these difficulties using the ExactWeld 430 machine.

The ExactWeld 430 is a turnkey solution for precision laser welding, featuring a fiber laser source, galvoscanner, and vision system. It can deliver precise laser pulses to weld thin wires with diameters as small as 25 µm. The machine's vision system enables automated processing, ensuring accurate alignment and weld gap control.

Coherent's application experts have successfully welded various combinations of nitinol and stainless steel wires using the ExactWeld 430. The process requires precise control of laser power, pulse duration, and temporal shape to achieve reliable welds without damaging the wires or any plastic coatings.

This application note explores how ExactWeld 430 offers customizable solutions for different welding applications, including contact welding, seam welding, and free-form welding. Its advanced features and precision capabilities make it a valuable tool for medical device manufacturers seeking to join thin wires of difficult-to-weld materials.