Build-up laser welding gets damaged mould tools back into shape quickly, with high quality and at low expense. The technique also enables existing tools to be altered.

Manufacturing tools and molds is an expensive procedure, and also very time-consuming. This is especially the case when a manufacturing tool has to be altered, or rebuilt because of damage. Build-up laser welding is the economical alternative.

The laser gets tools back into shape quickly, with high quality and at low expense.

Applications range from the repair of worn tools to design adaptations and build-up of complex contours.

'Laser welding has established itself as a reliable method, and is especially impressive for the durability of the applied material.

Refinishing work is minimal, and subsequent processing methods such as polishing or etching have no effect on the finished injection-molded component either', explains Michael Heinzmann, main application manager for tools and molds making at Trumpf Laser in Schramberg, Germany.

Trumpf provides systems specially designed for build-up laser welding, each adapted to the respective application.

Precise working with the Trumpf PowerWeld - 'All ergonomic factors were taken fully into account in the design of the laser workstation PowerWeld', according to Heinzmann.

This is important for precise, fatigue-free working.

Workpieces can be handled without a problem in the spacious working area of the PowerWeld.

The air-cushioned work surface ensures precise workpiece positioning and welding.

Various guidance systems and alignment aids can be retrofitted without a problem.

They include a joystick control, CNC programmable axes and also a motorized rotational axis, enabling precise application of contours according to coordinates.

The optional focus-finder allows the focal point to be pre-adjusted independently of the stereo microscope.

For simple loading of the working area, even with heavy workpieces, the air-cushioned work surface needs simply to be moved out of the working area onto an additional table.

More options and possibilities with the PowerWeld open and the Mobile Manual Laser Welding Device - the laser workstation PowerWeld open gives even more options where large and especially long, asymmetrical workpieces are concerned.

The working area is not closed off, enabling free access to the working surface as well as easy loading.

A processing optic that can be swiveled as well as moved in the y direction provides even more processing flexibility.

Mobile manual laser welding devices make it possible to process very large and heavy workpieces that should not be moved.

Here, the welding equipment is brought to the workpiece, rather than the other way around.

As the processing optic is guided by hand it can thus be adapted to the welding point location.

A camera integrated into the processing head visualizes the working area.

The operator can then follow an enlarged version of the process on a monitor.

Trumpf solid-state lasers for welding build-up - 'In connection with the processing systems TRUMPF pulsed solid-state lasers from 20 - 200 Watt are used' says Heinzmann.

The modular optic design on the laser devices, together with flexible laser light cables, make it possible to power several processing stations, such as the PowerWeld and a manual laser welding device, thus enabling one to enhance the other.