LASERAGE

Case Study #1 “Custom Laser welding of Faucet Mixing Ball”

At Laserage, our comprehensive laser services include custom laser welding, which provides a clean and efficient alternative to traditional welding methods. The distinguishing characteristic for laser welding is precision placement of the weld, with a minimal heat-affected zone on the joined assembly.

The drawing shown here is a stainless steel faucet mixing ball that we manufacture for a nationally regarded faucet company. The component measures 1” in diameter and has an overall length of 1.5”. The customer specified a minimum weld depth of 0.009” and a minimum width of 0.030” throughout the weld which attaches the stem to the ball half. The quality of the welds is verified using 100% pressure testing.

When the customer was quoting this part, they were initially looking at offshore suppliers. However, after researching offshore options, they arrived at the same conclusion as many customers who have contacted us over the years. By focusing on quality and efficiency, we are able to provide superior parts at competitive prices with turnaround times that are simply not possible to achieve using offshore sources. By continually providing the customer with premium quality parts and reliable service, this has evolved into a long-term job for us.

Today, we produce over 500,000 of these mixing balls per year and maintain a kanban system with five-day turnaround to ensure that these parts are always readily available. We take pride in knowing that our superior laser-welded components are used within faucets that can be found in hotel bathrooms in Pennsylvania, filling-station restrooms in Arizona and state park campground facilities in Minnesota. For additional information about this custom laser welding project, see the table below or contact us directly.

Product Description
Custom Laser Welding of a SS Faucet Mixing Ball

Capabilities Applied/Processes
Primary: Laser Welding

Equipment Used to Manufacture Part
CO2 Laser

Overall Part Dimensions
1” dia x 1-1/2”

Tightest Tolerances
Min depth weld-.009, min width .030

Material Used
Stainless Steel

In process testing/inspection performed
100% Pressure Testing

Volume
500,000/annually

Delivery/Turnaround Time
5 days/kanban release

Delivery Location
Southern USA (TN)

Standards Met
Customer supplied print, 2D CAD Drawing

Case Study #2 Custom Laser Drilling for Anesthetic Delivery System

At Laserage, we can easily accommodate requests for complex components requiring multiple laser fabrication techniques and secondary processes.

The drawing depicted here is a cannula tube that is used as part of anesthetic delivery system for medical applications. The cannula is constructed of a white polycarbonate tube that we mark and drill using laser-based technologies. The laser marking is used for orientation of the tube and the 24 holes are drilled in a spiral pattern for delivery of the anesthesia. After drilling, the tube is cleaned using a deionized surface cleaning process and the end of the tube is melted to form and cap the cannula end according to the customer-provided specifications.

The finished tube measures 0.12” in diameter and is 7.875” long. We are required to hold hole tolerances to as tight as ±0.002” for this precision application. The tubes are 100% inspected using an automated inspection system to verify the relation of the holes with the orientation laser marking. AQL inspections are performed on the offset of the holes at the end of the tube, the hole diameter, and the total number of holes, and additional inspections are regularly performed to verify the rotation of the hole pattern.

Through 35 years of service, we have produced more than one million of these cannula tubes annually for this internationally-based customer—which illustrates that we have exceeded the customers’ expectations every single delivery. For additional information about this custom laser drilling project, see the table below or contact us directly.

Product Description
Cannula, part of an anesthetic delivery system for throat.

Capabilities Applied/Processes
Primary: Laser drilling holes into plastic tube
Secondary: Laser marking for orientation, drill 24 holes into tube in a spiral pattern, run tube thru Deionized surface cleansing process, tip the end of the tube (melt end to create cap) and form.

Equipment Used to Manufacture Part
CO2 laser for holes, 1 micron laser for marks

Overall Part Dimensions
7.875” L x .12 dia

Tightest Tolerances
.006 +/-.002 hole

Material Used
White polycarb

In process testing/inspection performed
100% auto inspect to indicate holes are oriented to laser marks properly. AQL insp on offset of holes at end of part, AQL for # of holes on part, AQL hole dia. Reg occurring insp on rotation of holes.

Industry for Use
Medical

Volume
1,000,000+ annually

Delivery Location
Latin America (Costa Rica)

Standards Met
Customer supplied print, 2D CAD Drawing