Electrical / Arc Flash

High-Power Fiber Laser Enclosure — Automotive Tier 1 Supplier

Complete transparent protection system for a 6kW fiber laser welding cell serving electric vehicle battery tray production. Required full visibility for process monitoring, robotic integration, and operator safety compliance.

CLIENT

Stellantis Supplier Network

LOCATION

Detroit, MI, USA

Equipment Context

Protection Concern
& Viewing Requirement

Equipment Context
Existing robotic welding cell with IPG YLS-6000 fiber laser, two 7-axis FANUC robots, and rotary part positioner.
Protection Concern
6kW continuous-wave laser at 1064nm, risk of diffuse reflection. Current polycarbonate guarding only rated for CO2 lasers.
Viewing Requirement
Requires full-height visibility on three sides for robot teaching, process monitoring cameras, and manual inspection stations.

What We Did

Material Directs Fabrication to Integration

A three-phase approach moving from wavelength-specific material selection through precision fabrication to modular frame integration — all validated against the operating environment and robotic motion envelope.

Material Direction

Selected 1064nm-tuned laser acrylic vs. fused silica & glass laminate: cost, weight.

Wavelength verification at 1030–1080nm
Optical density measurement per EN 207
Thermal cycling validation (–20°C to +80°C)
Impact test: 45J ball drop, no penetration

Fabrication

CNC panels, sealing grooves, bosses. Edge-polished. Hard-coated on operator side.

Panel flatness: ±0.3mm over 1500mm
Integrated gasket groove, 3mm EPDM
Anti-static surface treatment applied
Protective film, peel-away on install

Structure & Integration

Modular Al frame, T-slots, 48h install. Interlocks, LED status, cable mgmt for cameras.

Frame: 40×80mm extrusion, anodized
Panel retention: quarter-turn fasteners
Interlock: 24V DC, SIL 2 rated
Camera ports: 3× pre-cut 80mm openings

Structure & Integration

Modular Al frame, T-slots, 48h install. Interlocks, LED status, cable mgmt for cameras.

Frame: 40×80mm extrusion, anodized
Panel retention: quarter-turn fasteners
Interlock: 24V DC, SIL 2 rated
Camera ports: 3× pre-cut 80mm openings

Specification

Technical Specifications

Material Laser-Grade Acrylic
LPA-1064-HC composite with embedded Nd absorber
Optical Density / Wavelength OD 7+ @ 1064nm
Tested per EN 207:2017, LB7 rating
Panel Size / Thickness 1500 × 2000 × 12mm
Max Single Panel, 4 Panels Per Cell Face
Frame / Mounting 40×80mm T-Slot
6063-T5 aluminum, clear anodized

Gallery

Process, Installation & Finished Views

From material preparation through final commissioning — documentation of the complete project lifecycle.

Outcome

Daily Use Deliverables

The enclosure has been in continuous production for 8 months with validated performance against all specification targets and zero safety incidents.