Laser Direct Structuring (LDS) of Large Parts

Laser Direct Structuring (LDS) has proven its series capability millions of times and has been continuously developed further. The LPKF Fusion3D 1500 is available for particularly long parts. The LPKF Fusion3D 1500 combines the performance of LPKF's high-performance structuring machines with the flexibility of a compact system.

Laser direct structuring enables new layouts

This is good for the manufacturer when fewer components are needed, which saves production costs and assembly time. But above all; it saves space. Laser Direct Structuring (LDS) has long proven its efficiency in smartphone antennas.

With LDS technology, individual components can be completely eliminated. With the LDS process, existing plastic components can also perform electronic functions in addition to their mechanical tasks.

Almost any plastic component can be precisely and safely provided with conductive tracks.

This turns a clip into a WLAN antenna, and active components can be placed on the back of the display cover. The entire laser system is optimized for this purpose. It has precise linear drives, a high-quality laser processing unit and room for further upgrades.

Proven technology

A solid granite block forms the basis, practice-proven technology ensures functionality. The LPKF Fusion3D 1500 presents itself as a system that transfers the proven LDS technology of smartphone antennas to larger components. All this takes place in a compact housing with handling.

The linear system with two drive trains moves the components into the machining area. Structures of up to 400 x 78 mm and a maximum height difference of 80 mm can be produced one after the other. While one strand is being processed with the laser, the second strand moves into position. This almost completely eliminates non-productive time.

Further performance gains are achieved by a multi-head laser system.

Simple component placement

The laser process itself is non-contact, which means that the requirements placed on the component fixtures are low compared to the tools used in other processes. The component fixtures only have to ensure the exact infeed of the component to the laser beam. The components are fixed in place by means of clamps or vacuum, and locating pins ensure precise positioning. In practice, repeatable accuracies of ± 25 μm are achieved over the entire structuring process.

LPKF advises on the design of component fixtures and offers their preparation. Each fixture set is extensively tested and handed over with a measurement protocol.

Low-maintenance linear drives

Not only particularly precise, but also particularly economical: The linear drives used are precisely matched to the laser process and impress with their long service life and minimal maintenance requirements.

The LPKF Fusion3D 1500 laser structuring system corresponds to laser class 1 in normal operation with a closed hood. The loading opening of the handling module is protected by a light curtain against manual intervention during the movement of the linear axes.

Powerful system software

From the layout program to the part: The LPKF CircuitPro 3D system software controls all laser structuring machines of the LPKF Fusion3D series. It takes over the data from the layout programs and allows the process order to be optimised. This eliminates additional non-productive time and increases production throughput.

Structuring large components

The laser is a precision tool that operates within a defined working area. Applications in the RF range, such as complex antennas, depend on an exact match between layout and processing result. The scan field of the processing unit is 160 x 160 x 80 mm (x, y, z). With a double feed, the width is 2 x 78 mm. Lengths that exceed the scan field are processed by stitching several structuring processes together.

Here, the LDS method plays a further advantage: This additive process - metallization is based on the structured surfaces - seamlessly bridges the connection areas.

Gain free capacities

For production planning, the LPKF Fusion3D 1500 is a major winner. Machining processes can hardly be designed more flexibly than with this system.

In laser direct structuring, loading a project file is enough to change the production process. The LPKF Fusion3D 1500 goes even further: it can use a different component fixture in each shuttle and also carry out different machining processes for these.

This means that two products can be run in parallel in one laser system, which is ideal when there is an urgent need for components. But this laser structuring machine is also suitable for the joint production of product pairs (e.g. right and left components).

Faster to the product

24/7 in an industrial environment - no problem for LPKF's tried and tested laser direct structuring machines. Trained service personnel are available worldwide for installation and servicing. LPKF creates solutions - together with its customers.