Clearweld Coating Material for Clear Plastic Laser Welding
Sono-Tek ultrasonic spray technology provides a precise, repeatable way to apply Clearweld coating material for Clear Plastic Laser Welding. Clearweld is a low-viscosity, infrared-absorbent solution designed to be deposited as a thin, uniform layer at the weld interface. When exposed to laser energy at the proper wavelength, the Clearweld layer absorbs the laser beam and generates localized heat, creating strong, clean weld seams between clear thermoplastic plastic parts.
Sono-Tek ultrasonic nozzles are used to spray Clearweld 100, Clearweld 200, and 900 Series materials in laser plastic welding applications where tight control of film thickness and line placement directly impacts weld quality.
Ultrasonic Spray for the Clearweld Welding Process
Clear plastic laser welding requires a highly controlled absorbent layer: thick enough to absorb laser transmission efficiently, but thin and uniform enough to maintain optical clarity and consistent weld performance. Ultrasonic spray is well-suited to this requirement because it atomizes low-viscosity solutions into fine droplets and deposits a repeatable coating pattern without clogging.
Key Sono-Tek capabilities for Clearweld applications include:
- Repeatable, controllable thin-film deposition of Clearweld coatings
- Stable atomized spray for uniform absorbent coverage
- Precise line application for consistent weld seams
- Low-waste coating with minimal overspray
- Easy integration into automated laser welding systems
Nozzle Options for Fine Lines and Wider Tracks
Different Clearweld coating patterns are used depending on part geometry and weld design.
- PicoMist ultrasonic nozzle — ideal for ultra-fine, narrow lines of Clearweld material where high precision is required. The PicoMist supports repeatable deposition along complex weld paths and small features.
- AccuMist with air shaping — used when wider weld tracks are needed. Air shaping allows controllable line width while maintaining thin, uniform Clearweld coatings.
Ultrasonic nozzles can be incorporated into programmable XYZ motion platforms (such as ExactaCoat MD) to form a fully integrated Clearweld coating and laser welding process.
Clearweld Features for Clear-on-Clear Laser Welding
Clearweld materials are engineered to enable reliable laser welding technology for transparent polymers:
- Clean, clear welds with minimal visible marking
- Low-viscosity infrared absorbing solutions
- Designed for consistent absorption of laser energy at the weld interface
For additional Clearweld material and application details, visit:
https://clearweld.com/distributors-equipment-and-manufacturers/
Integrated Systems for High-Quality Laser Plastic Welding
Sono-Tek ultrasonic coating systems are commonly paired with precision laser welding machines and laser systems to create a robust clear-on-clear welding system. By combining accurate Clearweld deposition with controlled laser parameters (beam delivery, energy, wavelength, and transmission path), manufacturers can achieve high-quality weld seams in demanding thermoplastic assemblies.
This approach is used in medical device manufacturing and also applies to other industries requiring strong, clean laser plastic welding of clear polymer components, including automotive applications.
Partner Laser Technology
ProByLas provides precision laser technology for clear-on-clear plastic joining, complementing Sono-Tek’s ultrasonic Clearweld coating process. For more information on ProByLas laser systems and plastic laser welding equipment, visit ProByLas AG. See how ProByLas can elevate your plastic welding process. Visit their YouTube channel to see their technology in action: https://www.youtube.com/@ProByLas
