Optoelectronics has made a major announcement! Plastic Welding Defect Detection Version 2.0 From surface welding inspection to internal three-dimensional reconstruction, redefining plastic welding quality standards

n today's era of widespread laser plastic welding, one critical issue has become increasingly evident:

The quality standards for plastic welding must be redefined.

For a long time, the industry has focused primarily on whether a product's functionality meets the required standards.

Yet it overlooks a fundamental question: what is the actual structural state of the weld?

Today, Weikrui Optoelectronics officially announced:

Non-destructive Defect Detection Version 2.0

This represents not just a product upgrade, but a fundamental elevation in our understanding of quality standards.

1. Current Industry Status: Weld seams are inherently invisible

In laser welding processes, most products employ a through-welding structure.

· The upper material is transparent to light.

· Lower-layer material absorption

· The weld seam is formed at the internal bonding interface.

The critical zone of welding is structurally invisible.

We cannot determine by appearance:

· Whether it is fully plasticized

· Is there a differential layer?

· Has any hollowing occurred?

· Is there any unmelted area?

Welding quality has long remained in an "invisible state."

II. Limitations of Traditional Detection Methods

The current mainstream detection methods include:

· Air tightness test

· Blasting Test

· Tension Test

These methods can only be evaluated based on the "results." They address the following questions:

Is it missing?

Is it off?

but cannot answer:

Has the welding interface truly reached the material fusion limit?

This also represents a long-standing structural blind spot within the industry.

III. What constitutes an excellent weld seam?

The essence of plastic welding lies in the diffusion and rearrangement of molecular chains.

A truly excellent weld should meet the following requirements:

The welding surface is perfectly plasticized, achieving a bond quality comparable to injection molding standards.

The specific structure is as follows:

· At the interface, it disappears.

· The plasticizing layer is continuous and uniform.

· No hollow drumming

· No layers

· No unmelted residue

Welding is not merely about "gluing" materials together; it involves the true integration of their structures into a unified whole.

IV. Diagram of Typical Structural Issues

Figure 1: Insufficient pressure causes hollowing

When the welding pressure is insufficient, the interface bonding is inadequate.

The molten layer cannot be fully compacted, resulting in internal voids after cooling.

configuration state ：

· There is a cavity inside.

· The interface does not fit completely

But traditional test results may show:

· meets the air-tightness requirements

· The pull strength meets the requirements.

This is a typical example of a "fake compliance structure."

Under prolonged thermal cycling or vibration fatigue conditions, such structures are highly susceptible to becoming crack initiation sites.

Figure 2: Actual weld under non-destructive defect testing

Using non-destructive testing techniques, the internal condition of the weld can be directly visualized:

· The plasticization zone is clearly visible.

· Accurate identification of hollow areas

· The non-matched areas are clearly visible at a glance.

For the first time, welding quality has evolved from being merely "estimated" to being "structurally visible."

Figure 3: A truly excellent weld seam

The ideal structure should be as follows:

· The interface surface is completely plasticized.

· The boundary line has disappeared

· Integrates seamlessly with the structure of the upper injection-molded component

· Internally continuous and dense

Under these conditions, the weld joint is no longer merely an interface between two materials.

Instead, it becomes a complete structural entity.

Figure 4: Layering observed within the weld seam

When energy distribution is uneven or cooling control is abnormal,

A layered structure may form inside the weld seam.

Structural risks include:

· Microcrack initiation

· Fatigue Expansion Channel

· Long-term reliability decreases.

This type of issue cannot be identified solely through traditional functional testing.

V. Version 1.0: Planar inspection of welded surfaces

Weikerui Optoelectronics Version 1.0 implements the following features:

· 100% Online Full Inspection

· Internal welding interface identification

· Defect detection on welding surfaces

· Identification of flat-level hollow areas

It can be understood as:

1.0 is the "planar inspection" of the welding interface.

It addresses the issue of whether the welding surface is continuous.

But still cannot be accessed:

· Axial fault information

· Changes in the thickness of the plasticizing layer

· Internal Layer Structure

1.0 Solves:

Was the welding successful?

However, this does not fully address the question: "Has the welding achieved structural-level integration?"

VI. Version 2.0: Axial section imaging + 3D structural reconstruction

The core breakthrough of version 2.0 lies in the enhancement of detection dimensions.

1. Axial section imaging

New axial tomography capability:

· Obtain structural information along the thickness direction

· Identify internal differential layers

· Assess the continuity of the plasticized region

· Position the structural breakpoint

The weld seam is no longer just a flat surface.

It is rather a three-dimensional structure with defined thickness and volume.

2. Three-dimensional imaging reconstruction

Through continuous fault data reconstruction, the following is achieved:

· Construction of a 3D model of the weld joint

· Visualization of the spatial distribution of the plasticized layer

· Quantification of hollow volume

· Precise positioning of layer length

Welding quality has officially entered the era of 3D structural-level validation.

VII. Industry Significance: The Evolution of Quality Definition

In the past, we asked:

Has the product passed testing?

The question for the future is:

Does the weld truly achieve a fusion state suitable for injection molding?

When the weld can be cut into cross-sections,

When a structure can be reconstructed in three dimensions,

Plastic welding: Key features for the first time:

· 100% capability to verify fully welded structures

· The upgrade path from random sampling to comprehensive testing

· The transition from functional compliance to structural reliability

epilogue

The plastic welding industry is undergoing a significant transformation:

From invisible to planar visualization, and then to three-dimensional structure reconstruction

Released by Weikrui Optoelectronics

Plastic Welding Defect Detection Version 2.0

It is not merely a testing system, but a comprehensive redefinition of quality standards.

The quality of a weld seam should not be inferred but must be clearly verified through its three-dimensional structure.

This time, the weld seam was truly visible.