Next-Generation Adaptive Laser Joining for Body -In -White: Adaptation, Monitoring and Performance

This presentation explores advancements in Laser Joining Technologies highlighting the integration of Scansonic’s Adaptive Laser Welding Optics and DINSE high-precision wire-feeding technology. This session will discuss application examples of Scansonic’s sensor-integrated optics in conjunction with DINSE fast PUSH PUSH response time wire feeders. Case studies will be used to illustrate results of interaction between tactile filler wire tracking and real-time controlled filler wire feed.

Laser welding enables high-reliability precision manufacturing across sectors including automotive, e-mobility, and medical devices. However, in large-scale production environments, systematic and random process variation can introduce weld defects that compromise performance and safety. In-process monitoring has consequently become important.

Many monitoring approaches (photodiode, acoustic) capture indirect signals and cannot directly resolve keyhole dynamics or penetration. Optical Coherence Tomography (OCT) offers a unique advantage as it enables real-time, non-destructive measurement of weld depth and geometry directly within the process zone – enabling 100% inline inspection.

This presentation reviews the state-of-the-art in industrial Spectral Domain OCT (SD-OCT) for laser process monitoring and introduces a recent advancement — ultra high-density OCT (UHD-OCT), which extends the capabilities of OCT by enabling deeper weld measurements and higher signal density. These innovations expand OCT’s applicability to emerging welding applications and higher power welding platforms, opening new possibilities for process monitoring and control in advanced manufacturing environments.

Traditional remote laser welding requires expensive, floor space consuming light tight safety cells to protect people in the production environment. This presentation introduces the Safe Component Welding (SCW) head: a disruptive solution that integrates a high-performance laser scanner into a portable, laser-safe encapsulated beam delivery optic. By "bringing the cell to the part," the SCW head enables high-speed laser welding in open production environments where traditional cells are impractical.

Initially developed for Body-in-White fixation points, the system solves the critical challenge of joining inner and outer hang-on parts without compromising Class A surface quality. Application examples will be discussed.