A die-casting die with a damaged edge often cannot be removed quickly. Pulling it from the press can cost half a shift and disrupt production. In such cases, a mobile workstation system rolls up to the machine, is positioned by one person, and the repair is completed on site. This approach avoids long downtimes and the risks of transporting large or sensitive parts. More details can be found in the overview of mobile laser welding systems.

Three situations where the system comes to the part

Mobile laser welding systems are used when the time, cost, or risk of moving a workpiece outweighs the benefits of a stationary setup. The three main situations are:

• The tool or mould is still in the press or injection moulding machine, and removal would cost hours of production.
• The part is too large, too heavy, or permanently installed to move, such as a machine bed, cast housing, or ship component.
• The repair is time-critical and every day of downtime would stop production or cause high losses.

Mobile does not mean freehand welding: wheeled 5-axis workstation with CNC and microscope

A mobile system from Sigma Laser is not freehand welding. It is a wheeled 5-axis workstation system (X·Y·Z·C·D) with CNC control, Leica 10× stereo microscope, program memory, and Super Pulse Technology. One person can position it 360° around the workpiece, and it welds under program control with the same quality as a stationary system.

Three systems cover different needs: Sineo Light uses an Nd:YAG laser with pulse energy up to 170 J, spot size 0.2–2.0 mm, travel 620 × 620 × 510 mm, and reach up to 1,830 mm. Sineo Fibre offers a pulsed and continuous wave ytterbium fibre laser with the same travel. Sirius Light is designed for heavy tools and large components, with a travel of 600 × 600 × 400 mm. All systems have an open frame, so there is no limit on part size or weight.

When a stationary system is the better choice

A stationary system remains the better choice for high production volumes, short cycle times, automation, or permanent integration into the line. These applications benefit from fixed installations and automated handling.

"From site visits, we see that mobile systems are chosen for flexibility and on-site repairs, but stationary systems are preferred for automated, high-throughput production," says Karsten Danzeisen, Senior Service & Support Engineer at Sigma Laser.

A sample weld on the customer’s own tool is offered before purchase, so the process can be tested in practice. Details on the Sineo Light system and application advice are available from Sigma Laser.