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Case study

Innovative Forward Automotive Lighting Design with Laser Welding Technology

A new era in automotive lighting is being pioneered with a cutting-edge approach to forward automotive lighting design. Incorporating advanced laser welding technology enhances the durability and performance of headlamp assemblies while contributing to sustainability efforts in the automotive industry.
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Task

Leverage polycarbonate and laser welding in headlamp technology

Our team initiated a project to propel mono-material headlamp technology forward by introducing laser welding as a more sustainable alternative to adhesive bonding. This collaboration with Emerson, a global technology company, promotes cost savings, weight reduction, and sustainability advantages through mono-material design.

Simultaneous laser welding has become a benchmark technology for welding of tail lamps. With the innovative material combination and unique mono-material concept developed by Covestro, it's now possible to extend benefits for laser welding from rear of the vehicle to front lightning applications.

Marian Blasko

Automotive Account Manager, Emerson

Challenge

Transition from adhesive bonding to laser welding

Headlamp assembly typically relies on adhesive bonding, but laser welding presents a more sustainable option. The development of advanced headlamp systems incorporates high-performance materials such as Makrolon® and Bayblend® to enhance overall performance. 

By introducing laser welding, the goal is to enhance the efficiency and performance of headlamp manufacturing. This transition not only promotes significant cost savings but also contributes to weight reduction, leading to improved vehicle fuel efficiency. Additionally, the use of laser welding aligns with sustainability goals by reducing the environmental impact associated with adhesive materials. 

Karen Guzman and Joshua Wagner explain the laser welding process of mono-material headlamps.

The Branson laser welding technology in combination with the unique properties of Makrolon® excelled across diverse testing scenarios, demonstrating the feasibility of a mono-material headlamp and innovation in automotive forward lighting.

Josh Wagner

Application Development Engineer, Covestro LLC

Solution

Proven sealing solution that provides cost saving and sustainable benefits

These collaborative efforts have resulted in groundbreaking advancements in automotive forward lighting design. By leveraging polycarbonate materials, advanced thermal conductivity, and laser welding technologies, these innovations promise enhanced sustainability, cost efficiency, and performance across the automotive industry. 

Through this partnership, Covestro and Emerson are setting new benchmarks in automotive lighting, driving the industry towards a more sustainable and efficient future.

We combined creative design, advanced processing techniques and high-performance resins to demonstrate the suitability of a mono-material headlamp, but these concepts can be applied to different vehicle applications as well.

Karen Guzman

Automotive Marketing Manager, Covestro LLC

Key Benefits

  • Sustainability Enhanced recyclability compared to adhesives
  • Precision Precise control over welding area
  • Cost effective Reduces material usage and increases production

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In the meantime, feel free to discover our innovative material solutions!

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