Optimization of laser welding through a new system from Trumpf

Even Better Welding Trumpf Innovation Enhances Quality and Performance in Laser Welding

2025-07-02 Source: Trumpf | Translated by AI 1 min Reading Time

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A new system from Trumpf optimizes laser welding by combining various capabilities, which are further explained by the team...

What you see here is a complete system package that, according to Trumpf, smartly enhances the laser welding of components. Read here to learn what this means ...(Image: Trumpf) — What you see here is a complete system package that, according to Trumpf, smartly enhances the laser welding of components. Read here to learn what this means ...
(Image: Trumpf)

Trumpf has emphasized that it has developed a new method to improve quality and efficiency in laser welding. The innovation combines multiple sensors to monitor all process steps of laser welding. An integrated AI quality control system inspects the weld seams, while an OCT (optical coherence tomography) checks the penetration depth of the laser beam, according to the company. Trumpf points out that this system is currently unique. The specialists also offer all components (beam source, sensors, and optics) from a single source. Trumpf takes care of the installation, service, and programming of the system, which can be tailored to the user, as further stated. Additional interfaces are rendered unnecessary, eliminating the usual and time-intensive coordination with various system suppliers.

Laser Focus Is Always Automatically at Its Optimum

Users can now weld those components even more precisely where errors are unacceptable. Consider, for example, batteries for electric cars or hairpins for electric motors. For flawless weld seams, the user must set the optimal working distance between various components and the laser. However, this is now made possible by the programmable focusing optic called PFO 33, which can independently adjust the focus position. This so-called 2.5D operation is also often more cost-effective than 3D operation, where the PFO would need to move up and down during the welding process.

From the very first part welded with a Trumpf laser, you're on the right track. Artificial intelligence, the PFO 33 focusing optics (shown here), and integrated optical coherence tomography (OCT) assist in this process.(Image: Trumpf) — From the very first part welded with a Trumpf laser, you're on the right track. Artificial intelligence, the PFO 33 focusing optics (shown here), and integrated optical coherence tomography (OCT) assist in this process.
(Image: Trumpf)

Less complex controls and programming, as well as fewer moving axes, logically reduce acquisition, operating, and maintenance costs. Additionally, it is faster for the optic to adjust the focus position itself rather than moving the entire optic up and down within the laser cell. To inspect the quality of the produced components, Visionline Inspect is also used. A camera captures an image of the weld seam, and the system uses artificial intelligence to detect potential defects. By combining AI preprocessing with conventional algorithms, Trumpf achieves traceability and transparency in laser welding.

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Date: 08.12.2025

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