Integration Without Friction – How a smart Thermography System Fits Seamlessly into Your Plastic Welding Process

Adding inline inspection often sounds like a complicated, costly retrofit. But what if you could implement 100% thermal monitoring into your existing plastic laser welding process- without increasing cycle time or changing your machine layout? LPKF offers exactly that: a modular, proven solution for inline and standalone integration that supports high-performance quality control with minimal disruption.

Deep dive into TherMoPro – Read the Whitepaper

Real-World Constraints in Manufacturing Environments

Production managers often hesitate to introduce inline inspection systems for three understandable reasons:

Fear of cycle time penalties

Concerns about mechanical integration

Doubts about system compatibility

TherMoPro from LPKF was especially developed to serve laser plastic welding processes and with these constraints in mind. Its modular architecture today allows fast and easy deployment across:

Inline conveyor-based systems (e.g. InlineWeld 6200)

Rotary table machines

Custom standalone solutions (e.g. PowerWeld 3600 / 4600)

Hardware Integration – Smart and Flexible

Depending on the system layout, the thermal cameras are mounted:

Above the welding area,

To the side of the housing,

Or on robot-guided axes.

The design prioritizes operator accessibility, machine safety, and unobstructed workspace. Retrofits are possible without redesigning your production cell.

The multicamera configurations (up to six thermal cameras) ensure full coverage - even for large or geometrically complex parts. But the tool integration is only half of the demand.

Software Integration and Data Handling

TherMoPro’s software framework seperates the solution from simple camera technology. It integrates seamlessly into the welding machine’s control system and is freely adjustable. From trigger signal to data evaluation, all steps happen in under 800 ms- usually within the idle time after welding.

Data is:

Matched to part IDs

Stored for each component

Exportable for quality documentation and analytics

An optional offline module allows engineers to monitor process trends, fine-tune thresholds, or review rejected parts—without interrupting production.

Learn More About TherMoPro

Designed for Retrofit and Scalability

Whether you're building a new production line or upgrading an existing one, TherMoPro offers:

Minimal installation effort

Compact footprint

Ready-to-use calibration tools

Fast setup with preconfigured inspection routines

Already in use across over 40 applications, the system proves that real-world integration is not a barrier—it’s a blueprint.

More than a camera tool: TherMoPro

Adding 100% inspection to your plastic laser welding line doesn’t have to be a challenge. With flexible hardware, fast processing, and easy control integration, TherMoPro makes quality monitoring as smooth as your production flow.