Micro Joining

Fraunhofer ILT researches and develops laser-based joining technology in which different processes are used, such as laser welding, laser soldering or laser bonding, depending on the material class. The institute continues to develop processes such as the precision welding of metals, plastic welding or glass and ceramic processing, and adapts them for industrial applications. One focal point lies in the development of high-performance energy storage systems: A laser can reliably generate electrical contacts of copper materials and dissimilar metal combinations – for example, for the construction of battery modules or packs. These connections are characterized by their ability to carry high current.

Special tunable lasers can be used to weld plastic-metal compounds for the automotive industry or transparent and highly crystalline plastics for electronics or medical technology particularly well. Thanks to innovative irradiation technologies, the thermal load on the workpieces remains low. In the field of display, lighting and sensor technology, lasers are also used to encapsulate electronic components, to weld transparent plastics without absorbers and to solder glass for hermetic packaging.

The services offered by Fraunhofer ILT in the field of joining technology range from customer-specific process development, integration in industrial plant engineering, services in the areas of simulation and diagnostics, and comprehensive consulting.

Micro Welding

• Micro welding of steel, copper, aluminum
• Welding of heterogeneous materials
• Micro joints for electrical and precision engineering

Soldering

• Micro soft soldering for electronic / electrical engineering
• Brazing of heterogeneous materials
• Selective glass soldering for display technology and photovoltaics

Bonding

• Si / glass joints
• Si / Si bonding
• Micro welding of dielectric materials
• Packaging solutions for sensor technology and microsystems technology

Plastics Welding

• Welding of contours and welding simultaneously
• Transparent / transparent joints
• Metal-plastic joints

Brackmann, F., Brosda, M., Seidenberg, M., Sonnenschein, J.:
Feasibility analysis for the application of conduction tracks on textiles by means of laser radiation.
Welding in the World 68, 1905-1912, (2023)
https://doi.org/10.1007/s40194-024-01712-w (Open Access)

Wortmann, C., Brosda, M., Häfner, C.:
Mechanical Investigation of Recyclability for Sustainable Use of Laser-Based Metal–Polymer Joints.
Journal of Manufacturing and Materials Processing 7(6), 210, (2023)
https://doi.org/10.3390/jmmp7060210 (Open Access)

Helm, J., Olowinsky, A., Gillner, A.:
Anlagentechnik und Prozessentwicklung zum kombinierten Laserstrahllöten und -schweißen elektrischer Leistungsverbinder.
SCHWEIßEN UND SCHNEIDEN 7, 472-481 (2023)

Wurzbacher, S., Mascher, M., Wagner, P., van der Straeten, K., Jüptner, U., Hopmann, C.:
Development of micro-form-fitted amorphous thermoplast/light metal hybrid components.
Journal of Manufacturing Processes 54(2), 255- 266, (2023)
https://doi.org/10.1002/mawe.202100346

Berges, J. M., van der Straeten, K., Jacobs, G., Berroth, J.:
Towards a Model-Based Approach for the Optimization of the Mechanical and Economical Properties of Laser-Based Plastic-Metal Joints.
Key Engineering Materials 934, 75-80 (2022)
https://doi.org/10.4028/p-wcv8f2

Nguyen, N.-P., Nayak, C., Brosda, M., Olowinsky, A., Leitte, H., Gillner, A.:
Process monitoring in laser transmission welding of plastics by using deep learning algorithms.
LPM2021 -the 22nd International Symposium on Laser Precision Microfabrication, June 8-11, 2021, Web Conference.
The Proceedings of LPM2021, #21-038- (7 S.), (2021)

Kappert, H., Schopferer, S., Döring, R., Ziesche, S., Olowinsky, A., Naumann, F., Jägle, M., Ostmann, A.:
A7.1 Smart Sensor Systems for Extremely Harsh Environments.
Sensors and Measurement Science International SMSI 2021, 3 - 6 May 2021, Nuremberg Exhibition Center, Germany, 81-82, (2021)
http://dx.doi.org/10.5162/smsi2021/a7.1

Wagner, J., Hagenlocher, C., Hummel, M., Olowinsky, A., Weber, R., Graf, T.:
Synchrotron X-ray Analysis of the Influence of the Magnesium Content on the Absorptance during Full-Penetration Laser Welding of Aluminum.
Metals 11(5), 797- (13 S.), (2021)
http://dx.doi.org/10.3390/met11050797  (Open Access)

Berges, J. M., van der Straeten, K., Jacobs, G., Berroth, J., Gillner, A.:
Model-Based Estimation of the Strength of Laser-Based Plastic-Metal Joints Using Finite Element Microstructure Models and Regression Models.
Materials 14(17), 5004- (13 S.) (2021)
https://doi.org/10.3390/ma14175004  (Open Access)

Nguyen, N.-P., Nayak, C., Brosda, M., Olowinsky, A., Leitte, H., Gillner, A.:
Process Monitoring in Absorber-Free Laser Transmission Welding of Plastics by Using Deep Learning Algorithms.
Journal of Laser Micro/Nanoengineering 16(3), 166-172, (2021)
https://doi.org/10.2961/jlmn.2021.03.2003

Aden, M., Heinen, P, Olowinsky, A.:
Seam formation in laser beam micro-welding with spatial power modulation.
Lasers in Manufacturing and Materials Processsing 8, 60-72, (2021)
https://doi.org/10.1007/s40516-021-00137-3

Nguyen, N.-P., Behrens, S., Brosda, M., Olowinsky, A., Gillner, A.:
Modelling and thermal simulation of absorber-free quasi-simultaneous laser welding of transparent plastics.
Welding in the World 64, 1939-1946 (2020)
https://doi.org/10.1007/s40194-020-00973-5

Nguyen, N.-P., Behrens, S., Brosda, M., Olowinsky, A., Gillner, A.:
Laser transmission welding of absorber-free semi-crystalline polypropylene by using a quasi-simultaneous irradiation strategy.
Welding in the World 64, 1227-1235 (2020)
https://doi.org/10.1007/s40194-020-00913-3

Nguyen, N.-P., Brosda, M., Olowinsky, A., Gillner, A.:
Absorber-Free Quasi-Simultaneous Laser Welding For Microfluidic Applications.
JOURNAL OF LASER MICRO/NANOENGINEERING 14, 255-261 (2020)
https://doi.org/10.2961/jlmn.2019.03.0009

Spancken, D., Laveuve, D., Beck, J., Stötzner, N., van der Straeten, K., Büter, A., Henning, F.:
Hybrid materials - Joining of polymers and metals.
18th European Conference on Composite Materials, Athens, Greece, 24-28th June 2018. Proceedings of ECCM18, (8 S.), (2020)

Thoss A., van der Straeten, K.:
Joining composites and metal: A laser process.
INDUSTRIAL LASER SOLUTIONS, 8-9 (2020)

Hollatz, S., Kremer, S., Ünlübayir, C., Sauer, D., Olowinsky, A., Gillner, A.:
Electrical modelling and investigation of laser beam welded joints for lithium-ion batteries.
Batteries 6(2), 1-12 (2020)
https://doi.org/10.3390/batteries6020024

Hollatz, S., Heinen, P., Limpert, E., Olowinsky, A., Gillner, A.:
Overlap joining of aluminium and copper using laser micro welding with spatial power modulation.
Welding in the World, 24 (12 S.), (2020)
https://doi.org/10.1007/s40194-020-00848-9

Mamuschkin, V., Aden, M., Olowinsky, A.:
Investigations on the Interplay Between Focusing and Absorption in Absorber-Free Laser Transmission Welding of Plastics.
Lasers in Manufacturing and Materials Processsing 6, 113-125, (2019)
https://doi.org/10.1007/s40516-019-00083-1

Nguyen, N.P., Otto, G.:
Laserdurchstrahlschweißen transparenter Kunststoffe - Teil 3: Technisch-wirtschaftliche Aspekte
Laser transmission welding of transparent plastics - Part 3: Techniscal and economic aspects.
JOINING PLASTICS -FUEGEN VON KUNSTSTOFFEN 13, 176-181 (2019)

Engelmann, C., Gardiner, G., Voithofer, J., Popow, V., Weidmann, S., Eckstädt, J.:
Automated joining of hybrid metal-thermoplastic composite structures.
CompositesWorld 10, 24-31 (2019)

Nguyen, N., Brosda, M., Olowinsky, A., Gillner, A.:
Absorber-free quasi-simultaneous laser welding of transparent microfluidic devices.
LAMP-8th International Congress on Laser Advanced Materials Processing, 21.- 24.5.2019, Hiroshima Japan. Proceedings of LAMP2019, Micro Welding, 19-035 (Th33-L14, A120263), (7 S.) - (2019)

Engelmann, C., Hopmann, C., Wurzbacher, S.:
Laserstrahlmikrostrukturierung von Magnesiumblechen aus ME20 – Potenziale für die In-Mould-Assembly
von Kunststoff/Magnesium-Hybridverbindungen.
JOINING PLASTICS -FUEGEN VON KUNSTSTOFFEN 13, 182-189 (2019)

Helm, J., Dietz von Bayer, I., Olowinsky, A., Gillner, A.:
Influence of the surface properties of the connector material on the reliable and reproducible contacting of battery cells with a laser beam welding process.
Welding in the World, 1-8 (2019)
https://doi.org/10.1007/s40194-019-00727-y

Heinen, P., Eichler, F., Haeusler, A., Olowinsky, A., Aden, M., Gillner, A., Poprawe, R.:
Influence of spatial power modulation on pore and crack formation in laser beam welding of aluminum.
Journal of Laser Applications 31(2), 22013- (2019)
https://doi.org/10.2351/1.5085460

van der Straeten, K., Sparla, J., Olowinsky, A., Gillner, A.:
Influence of Self-Organizing Microstructures on the Wettability of Molten Plastic on Steel for Hybrid Plastic-Metal-Joints.
Welding in the World 63, 1221-1228, (2019)
https://doi.org/10.1007/s40194-019-00765-6 (Open Access)

van der Straeten, K., Olowinsky, A., Gillner, A.:
Laser-based plastic-metal-joining with self-organizing microstructures considering different load directions.
Journal of Laser Applications 30(3), 32401- (2018)
https://doi.org/10.2351/1.5040616

van der Straeten, K., Nottrodt, O., Zuric,M., Olowinksy, A., Abels, P., Gillner, A.:
Polygon scanning system for high-power, high-speed microstructuring.
Procedia CIRP 74, 491-494 (2018)
https://doi.org/10.1016/j.procir.2018.08.137

van der Straeten, K., Olowinsky, A., Gillner, A.:
Influence of Climatic Changes on the Joint Strength of Laser Joined Plastic-Metal-Hybrids.
Journal of Laser Micro/Nanoengineering 13(3), 287-291 (2018)
https://doi.org/10.2961/jlmn.2018.03.0024

Spancken, D., van der Straeten, K., Beck, J., Stötzner, N.:
Laserstrukturierung von Metalloberflächen für Hybridverbindungen.
Lightweight Design 11(4), 16-23 (2018)
https://doi.org/10.1007/s35725-018-0031-1

Spancken, D., van der Straeten, K., Beck, J., Stötzner, N.:
Laser Structuring of Metal Surfaces for Hybrid Joints.
Lightweight Design 11(4), 16-21 (2018)
https://doi.org/10.1007/s41777-018-0028-6

Engelmann, C., Molitor, T.:
Diodenlaser ebnet Weg zu Hybrid-Bauteilen. Reproduzierbares quasisimultanes Laserfügen ersetzt Klebeprozesse.
KUNSTSTOFFE 5, 90-93 (2018)

Nguyen, N., Brosda, M., Olowinsky, A., Gillner, A.:
Localised modifications inside polycarbonate and polyethylene terephthalate by using ultra short laser pulses for microwelding applications.
The 19th International Symposium on Laser Precision Microfabrication Edinburgh Conference Centre, Heriot-Watt University, Edinburgh, UK, 25-28 June, 2018. Proceedings of LPM2018, #18-033, (4 S.), (2018)

Nguyen, P., Fatherazi, P., Nippgen, S., Brosda, M., Olowinksy, A., Gillner, A.:
Investigations on energy deposition in polycarbonate by picosecond laser pulses for welding applications.
Procedia CIRP 74, 315-319 (2018)
https://doi.org/10.1016/j.procir.2018.08.122

Chung, W., Häusler, A., Olowinsky, A., Gillner, A., Poprawe, R.:
Investigation to Increase the Welding Joint Area with Modulated Laser Beam Welding over Gap.
Journal of Laser Micro/Nanoengineering 13, 117-125 (2018)
https://doi.org/10.2961/jlmn.2018.02.0011

Heinen, P., Haeusler, A., Mehlmann, B., Olowinsky, A.:
Laser beam microwelding of lithium-ion battery cells with copper connectors for electrical connections in energy storage devices.
Lasers in Engineering 36, 147-167 (2017)

Schmitt, F., Olowinsky, A.:
Chapter 26: Laser Beam Micro-Joining.
Micromanufacturing engineering and technology, second edition.
In: Qin, Yi (Ed.): Micromanufacturing Engineering and Technology (Second Edition), 613-635 (2015)
https://doi.org/10.1016/B978-0-323-31149-6.00026-8

Britten, S., Wein, S., Olowinsky, A., Gillner, A.:
Laser impulse metal bonding with temporal power modulation
PCIM Europe 2015, Nürnberg, May 19 – 21 (7 S.) (2015)

Britten, S. W., Wang, A. Y.-T., Olowinsky, A., Gillner, A.:
Measurement of the vapor plume velocity in Laser Impulse Metal Bonding with temporal power modulation
LAMP 2015 – the 7th International Congress on Laser Advanced Materials Processing, Kitakyushu, Fukuoka, Japan, (7 S.) (2015)

Engelmann, C., Meier, D., Olowinsky, A., Kielwasser, M.:
Metal meets composite - hybrid joining for automotive applications
LIM 2015 - Lasers in Manufacturing, Munich, June 22-25 (10 S.) (2015)

Kind, H., Gehlen, E., Aden, M., Olowinsky, A., Gillner, A.:
Laser glass frit sealing for encapsulation of vacuum insulation glasses
Physics Procedia 56, 673-680 (2014)
https://doi.org/10.1016/j.phpro.2014.08.075

Mamuschkin, V., Olowinsky, A., Britten, S., Engelmann, C.:
Investigations on laser transmission welding of absorber-free thermoplastics
Proc. SPIE  8968, (9 S.) (2014)
https://doi.org/10.1117/12.2039703

Mehlmann, B., Gehlen, E., Olowinsky, A., Gillner, A.:
Laser micro welding for ribbon bonding
Physics Procedia 56, 776-781 (2014)
https://doi.org/10.1016/j.phpro.2014.08.085

Mehlmann, B., Olowinsky, A., Thuilot, M., Gillner, A.:
Spatially modulated laser beam micro welding of CuSn6 and nickel-plated DC04 steel for battery applications
JLMN J. Laser Micro/Nanoeng. 9 (3), 276-281 (2014)
https://doi.org/10.2961/jlmn.2014.03.0019

Aden, M., Mamuschkin, V., Olowinsky, A., Glaser, S.:
Influence of Titanium dioxide pigments on the optical properties of polycarbonate and polypropylene for diode laser wavelengths
J. Appl. Polymer Sci. 131(7), (5 S.) (2013)
https://doi.org/10.1002/app.40073

Britten, S., Olowinsky, A. Gillner, A.:
Stress-minimized laser soldering of h-pattern multicrystalline silicon solar cells
Physics Procedia 41, 153-163 (2013)
http://dx.doi.org/10.1016/j.phpro.2013.03.064

Wissinger, A., Olowinsky, A., Gillner, A., Poprawe, R.:
Laser transmission bonding of silicon to silicon with metallic interlayers for wafer-level packaging
Microsyst. Technol. 19 (5), 669-673 (2013)
https://doi.org/10.1007/s00542-012-1636-4

Mehlmann, B., Olowinsky, A., Thuilot, M., Gillner, A.:
Spatially modulated laser beam micro welding of CuSn6 and nickel-plated DC04 steel for battery applications
Proc. of Lamp2013 - the 6th Int. Congr. on Laser Advanced Materials Processing (7 S.) (2013)

Wissinger, A., Olowinsky, A., Gillner, A., Poprawe, R.:
Laser transmission bonding of silicon with metallic interlayers for wafer-level packaging
Microsyst. Technol. 19, 669-373, (2012)
https://doi.org/10.1007/s00542-012-1636-4

Kind, H., Olowinsky, A., Gehlen, E.:
Laserprozess statt Ofenlötung.
Laser + Produktion, 30-32, (2011)

Olowinsky, A., Boglea, A.:
Extending the process limits of laser polymer welding with high-brilliance beam sources (recent status and prospects of POLYBRIGHT).
Proc. SPIE 7921, 792107, (15 S.) (2011)
https://doi.org/10.1117/12.874554

Olowinsky, A., Kind, H.:
Laser glass frit bonding for hermetic sealing of glass substrates and sensors
LPM 2010 - 11th International Symposium on Laser Precision Microfabrication, Stuttgart , 07. - 10. Juni 2010. (4 S.) (2010)

Schmitt, F., Olowinsky, A.:
Laser beam micro-joining
In: Yi Quin: Micromanufacturing Engineering and Technology. Norwich, N.Y.: W. Andrew Publ. pp. 185-201, (2010). ISBN 978-0-8155-1545-6

Schmitt, F., Mehlmann, B., Gedicke, J., Olowinsky, A., Gillner, A., Poprawe, R.:
Laser beam micro welding with high brilliant fiber lasers
J. Laser Micro/Nanoeng. 5 (3), 197-203 (2010)
https://doi.org/10.2961/jlmn.2010.03.0003

Stache, N. C., Stollenwerk, A., Gedicke, J., Olowinsky, A., Knepper, A., Aach, T.:
Automatic calibration of a scanner-based laser welding system
J. Laser Appl. 21 (1), 10-15, (2009)
https://doi.org/10.2351/1.3071317

Georgiev, G. L., Baird, R. J., McCullen, E. F., Newaz, G., Auner, G., Patwa, R., Herfurth, H.:
Chemical bond formation during laser bonding of Teflon (R) FEP and titanium
Appl. Surf. Sci. 255 (15), 7078-7083, (2009)
https://doi.org/10.1016/J.APSUSC.2009.03.046

Schmitt, F. Mehlmann, B., Gedicke, J., Olowinsky, A., Gillner, A., Poprawe R.:
Laser beam micro welding with high brilliant fiber lasers
Proc. of LAMP 2009 – 5th Int. Congr. on Laser Advanced Materials Processing, June 29 - July 2, 2009, Kobe, Japan, (6 S.) (2009)

Schmitt, F., Schulz-Ruthenberg, M., Olowinsky, A., Gillner, A.:
Laser joining process for photovoltaic module production
Proc. of the 5th Int. WLT-Conf. on Lasers in Manufacturing 2009, Munich, June 15 18, 2009. Ed. by A. Ostendorf [u.a.], Stuttgart: AT-Fachverlag pp. 625-630 (2009)

Sari, F., Flock, D., Gillner, A., Poprawe, R., Haberstroh, E.:
Laserdurchstrahlfügen für Mikrosysteme und Halbleitertechnik
4. Kolloquium Mikroproduktion. Hrsg. F. Vollertsen, S. Büttgenbach, Bremen: BIAS Verl. (12 S.) (2009)

Poprawe, R., Schmitt, F., Gedicke, J., Mehlmann, B., Olowinsky, A., Gillner A.:
Systemtechnik zur örtlichen Leistungsmodulation beim Laserstrahl-Mikroschweißen.
4. Kolloquium Mikroproduktion. Hrsg.: F. Vollertsen, [u.a.], Bremen: BIAS Verl. (10 S.) (2009), 10 S.

Schmitt, F., Funck, M., Boglea, A., Poprawe, R.:
Development and application of miniaturized scanners for laser beam micro-welding
Microsystem Technol. 14, 1861-1869, (2008)
https://doi.org/10.2351/1.5057115

Schmitt, F., Funck, M., Boglea, A., Poprawe, R.:
Development and application of miniaturized scanners for laser beam micro welding
Proc. of PICALO 2008, 3rd Pacific Int. Conf. on Applications of Lasers and Optics, April 16-18, 2008, Bejing, China, 727-732, (2008)

Stache, N., Dieckelmann, J., Firnich, R., Gedicke, J., Abels, P., Olowinsky, A., Aach, T.:
High speed video-based melt pool surveillance in laser spot welding
Proc. of the 27th Int. Congress on Applications of Lasers & Electro-Optics 2008, ICALEO, Temecula, CA, USA, October 20-23, (2008)
https://doi.org/10.2351/1.5061371

Schmitt, F., Prießner, A., Krämer, B., Gillner, A.:
Laser joining photovoltaic modules
Ind. Laser Solutions 23, 20-23, (2008)

Gillner, A.:
Laser micro processing
Laser Technik J. 5, 27-30, (2008)
https://doi.org/10.1002/latj.200790202

Sari, F., Wiemer, M., Bernasch, M., Bagdahn, J.:
Laser transmission bonding of silicon-to-silicon and silicon-to-glass for wafer level packaging and Microsystems
ECS Trans. 16, 561-568, (2008)
https://doi.org/10.1149/1.2982911

Albus, P., Boglea, A., Burbaum, B., Holtkamp, J., Kelbassa, I., Nazery-Goneghany, V., Olowinsky, A., Petring, D., Poggel, M., Schmitt, F., Schneider, F., Wolf, N., Poprawe, R.:
Neue Schweißtechnologien mit neuen Lasern
Proc. of 10th International Aachen Welding Conference iASTK´07, 229-242, (2007)

Stache, N. C., Zimmer, H., Gedicke, J., Regaard, B., Olowinsky, A., Knepper, A., Aach, T.:
Approaches for High-Speed Melt Pool Detection in Laser Welding Applications.
Proceedings of VMV 11, 217-224, (2006)

Gedicke, J., Regaard, B., Klages, K., Olowinsky, A., Kaierle, S.:
Comparison of different process monitoring methods for laser beam micro welding
Proceedings of ICALEO 2006, (8 S.) (2006)
https://doi.org/10.2351/1.5060910

Gedicke, J., Regaard, B., Gillner, A., Kaierle S.:
Kontrolle beim Mikroschweißen - Automatisierte Prozessüberwachung durch koaxiale Prozesskontrolle mit Fremdbeleuchtung
Laser Technik Journal 3, 33-37, (2006)
https://doi.org/10.1002/latj.200790120

Haberstroh, E., Hoffmann, W.-M., Poprawe, R., Sari, F.:
Laser transmission joining in microtechnology
Microsystem Technologies 12, 632-639, (2006)
https://doi.org/10.1007/s00542-006-0096-0

Gillner, A., Klages, K., Sari, F.:
Mikrofügen mit Laserstrahlung
Laser Technik Journal 3, 39-43, (2006)
https://doi.org/10.1002/latj.20079010

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