In laser welding, two things in particular influence the welding quality: the laser and the clamping device that holds the workpiece in place. Schnelldorfer Maschinenbau will show you what is important in laser welding clamping fixtures, how they are manufactured and what types of fixtures are available. For an all-round successful welding process.
Why the right device makes such a difference in laser welding
Everything has to fit together very precisely during laser welding: The laser only hits a small area, which is why the components must not slip or be crooked. Even the slightest inaccuracy can result in the heat not reaching where it is needed. This results in poorer weld seam results, more rework and, in the worst case, even rejects.
A high-quality laser welding clamping device reduces these risks. It holds the workpiece steady and securely in position. As a result, welding is cleaner and distortion is less likely to occur. The use of a fixture also has a direct effect on production: The workpieces can be inserted more quickly, clamped securely and removed again without the need for laborious readjustment. As a result, production is much more stable and the results are more consistent - and less time is lost for corrections.
Which clamping device is suitable for laser welding?
Which device makes sense depends heavily on the component and the process. A simple sheet metal part, for example, has completely different requirements than a heavy workpiece and a small series needs more flexibility than automated series production. This is why there is not one suitable clamping device for all applications, but several types with different strengths.
Types of clamping devices for laser welding
| Type of clamping device | Description | Suitable for |
| Magnetic clamping systems | Quick to use and good for simple sheet metal parts. However, not always the first choice for very high precision and alignment requirements. | Simple geometries, quick fixing, lightweight components |
| Pneumatic clamping devices | Fix workpieces quickly, evenly and with repeat accuracy and are therefore well suited for automated processes. | Series production, automated systems, recurring components |
| Hydraulic systems | Have high holding forces and are particularly useful when heavier components need to be securely clamped. | Large or heavy workpieces, high clamping forces |
| Mechanical clamping and screwing devices | Robust, easy to understand and easy to control in daily use. | Universal use, manual production, manageable series production |
| Modular clamping systems | Can be flexibly adapted and are particularly practical for many variants, changing geometries and smaller quantities. | Small series, prototype construction, multi-variant production |
What is important when designing a laser welding clamping fixture
Once the right type of fixture has been selected, the actual detailed work begins. Because it is not enough for a clamping device to simply hold somehow - it must guide, support and fix the component in such a way that laser welding works consistently and reliably. For this reason, the position, height and joining gap must be considered from the outset. If these points are not correct, even the most precise laser will not deliver good results in the long term.
It is also important that the welding point remains easily accessible. The fixture must not obstruct the laser beam and must also take into account the shielding gas, the sensors or the clamping points. At the same time, however, the fixture should be designed in such a way that employees or robots can easily insert and remove the components at any time.
Last but not least, the material of the fixture also plays a role that is often neglected. The reason: heat is generated during welding and this heat can affect the components of the fixture. Therefore, the more stable the fixture remains under the process conditions, the better repeatable results can be achieved.
When conventional devices reach their limits
Classic clamping, screwing or tensioning systems are often sufficient for simple components. However, things become more difficult when the geometries become more complex, components are very delicate or additional functions need to be integrated directly into the fixture. Then it can become complex and additional production is required: additive manufacturing. Although this does not replace the classic clamping device, it can be a useful addition.
Additive manufacturing in fixture construction: more freedom for complex tasks
In additive manufacturing, a component is not milled out of a block, but built up layer by layer. This is done using 3D metal printing, in which the device is created directly from digital design data. This makes it possible to create complex shapes that would be difficult to produce using conventional machining. The advantage of this technology is therefore obvious: freedom of design.
This opens up completely new possibilities in fixture construction: Complex geometries, internal channels or integrated functions can be planned directly and then implemented. For example, gas supply lines can be built directly into the laser welding device so that the shielding gas can reach the seam. Additive manufacturing also scores points in terms of weight, as the fixtures are generally lighter and ideally suited to lightweight construction and delicate sheet metal components. The lighter fixtures are also easier to move, quicker to retool and easier to use in robot systems.
All of this shows that 3D metal printing can be a strong support in the production of clamping fixtures, as it helps to develop the fixtures faster and bring them to series maturity.
Possible advantages of additive manufacturing at a glance
- More freedom with complex geometries
- Integrated functions such as shielding gas supply
- Lighter devices for robots and moving systems
- Faster prototypes and customizations
- Shorter time-to-market due to fewer development loops
- Better transfer of new assemblies to series production
Does it make economic sense? Then a clamping device is worthwhile
Whether a particular clamping device pays off depends on more than just the purchase price. It is just as important how strongly and positively it influences production, production time, reworking and the entire process chain.
To see whether a clamping device is worthwhile, check the following points:
- Design effort: How much time and effort goes into development and design?
- Manufacturing costs: What costs are incurred for the material and processing, assembly and testing?
- quantities: Is a customized solution worthwhile or does a flexible system make more sense?
- Set-up time: How quickly can the device be adapted to new workpieces or assemblies?
- Rejects and rework: How much does the device improve quality and how much does it reduce errors?
- Amortization: How quickly does the device pay for itself over the actual entire series?
Schnelldorfer Maschinenbau: Laser welding as part of sophisticated overall systems
Schnelldorfer Maschinenbau develops welding solutions that go beyond the individual machine. We focus on the skillful interaction of system, device, handling and automation - something that is particularly important in laser welding. Because as a specialist company, we know: Precision is only achieved when all components are perfectly coordinated. That's why we don't plan your welding system according to a set plan, but to suit your requirements and your business. For systems and clamping technology that work perfectly and remain easy to operate and economical in daily use at all times.
Find the right clamping device for laser welding with Schnelldorfer Maschinenbau
Finding the right clamping device for laser welding is not always easy - which is why we at Schnelldorfer Maschinenbau are happy to help you and your company. Our experienced specialists have a trained eye for your entire welding process, from component pick-up to handling and integration into the system. We are at your side with advice at eye level and develop systems on request that are perfectly tailored to your production and always work reliably, repeatably and precisely.
Are you planning a laser welding application or would you like to improve your existing production or welding fixture? Then contact us - we will be happy to advise you and develop the fixtures and clamping concepts that really fit.
Frequently asked questions (FAQ)
How often should a clamping device for laser welding be serviced?
Clamping surfaces, guides, clamping points and reference points should be checked at fixed intervals for wear, cleanliness and dimensional accuracy, as tight tolerances are particularly important in laser welding.
What are the disadvantages of laser welding?
Laser welding is often more expensive to purchase and requires high safety measures. The process is also sensitive to poor part quality, inaccurate gaps or inadequate preparation. However, laser welding scores with very precise seams, low heat input, a high welding speed and is also easy to automate.
Can you laser weld without gas?
No, a shielding gas is generally used for laser welding. It protects the weld pool and supports the seam quality. Without this appropriate gas flow, the quality of the laser weld seam can be significantly reduced.
Why does spatter occur during laser welding?
Splashes are usually caused by unstable process control, incorrect parameters or unfavorable surface conditions. With clean workpieces, a stable fixture and a precisely designed device, you can reduce the risk of splashes accordingly.
What is hybrid laser welding?
Hybrid laser welding combines laser welding with another welding process, usually MIG/MAG. This allows the high precision and speed of the laser to be combined with better gap bridging and higher material deposition.
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