Research Projects

Foram Dave

Current PhD Student

Investigate Optimal Laser Parameters for the Laser Transmission Welding of Semi-crystalline Polymers & their Composites


Laser Transmission welding (LTW) of polymers is one of the smart manufacturing techniques of Industry 4.0, which is used to join polymeric components with varying thickness and configuration using a laser source. They are widely used in industries like automotive, microelectronics, aerospace, medical, packaging, optoelectronics, microsystems, etc. The key advantages of LTW considering the industrial prospective are reproducibility of the process due to no wear and tear of the tool and increase in the productivity with better quality. It is a non-contact, flexible and easily controllable process with almost no contaminations. This technique requires one part to be laser transmissive and the other part to be laser absorptive, as shown in Figure 1. The two parts are under clamping force while the laser beam moves with defined parameters: laser power, welding speed, spot diameter, etc. resulting in inter-diffusion and microstructural change leading to the formation of weld joints. The effect of carbon black (size, shape, structure, thermal conductivity, dispersion, distribution, etc.) in the laser absorptive part and nucleating agent in the laser transmissive part and its processing conditions impacting the weld strength which needs to be characterised. Through laser, localised and narrow heat zone can be created. LTW has excellent potential in polymer joining applications and the challenges including the cost-effectiveness and innovative ideas provide the state-of-the-art in design and fabrication of the complex products in a wide range of applications.


  • Reduce scrap rate (bottle leaks)
  • Reduce welding cycle time
  • Increase productivity

Figure 1.Interaction of laser radiations with semi-crystalline polymers during the LTW process










Profile links:


  • Ulster University, Belfast, UK
  • Materials Research Institute, Athlone Institute of Technology
  • Abbott Diagnostics, Sligo, Ireland
  • Abbott Diagnostics, Chicago, US