Non-Destructive and 100% Inline: How Thermography Is Transforming Quality Control of Laser Plastic Welding

From Random Sampling to Smart Monitoring 

Plastic laser welding processes, especially contour welding, often lack complete process transparency. Traditional inspection methods rely on: 

• Visual checks 

• Destructive testing on samples 

• Occasional leak tests 

• One-time Thermal Stress test 

These approaches carry major risks: 

• Critical defects may go undetected 

• Initial quality doesn’t predict field performance 

• Costly recalls and product failures become likely

Specialized Thermography Makes True Quality Visible 

TherMoPro introduces long-wave infrared thermography directly after the welding process. Cameras capture the thermal footprint on the component’s surface. While the weld seam’s interior remains hidden, the surface temperature reliably indicates whether enough energy has reached the joint to ensure proper bonding. 

More than 20 thermal parameters are analyzed by LPKF’s proprietary software, including: 

• Heat distribution patterns 

• Local overheating or underheating 

• Anomalies indicating weak welds 

Key Benefits for Process Owners 

From Inspection to Prediction 

TherMoPro doesn’t just detect bad welds - it predicts process deviations before they result in defects. Intelligent trend analysis reveals subtle changes in materials, machine parameters, or part positioning early on. 

This shifts quality control from reactive to proactive process optimization, enabling: 

• More stable processes 

• Reduced scrap 

• Faster setup and validation 

Making Visible The Invisible 

TherMoPro brings the invisible into view: it makes heat transfer measurable, weld quality assessable, and trends detectable. For industries that demand high reliability and efficiency - like automotive, medical devices, and aerospace - this is a game-changer for quality and growth.