Gaps between joining partners can lead to defects in laser transmission welding of polymers. This paper presents a theoretical analysis of gap bridging during the laser transmission welding of polycarbonate. The model predicts the maximum allowable gap and maximum temperature as a function of carbon black level, laser power, and laser scan speed. The predictions agree with the experimental data. The model can help optimize material and process parameters for gap bridging in high speed contour welding of polymers.
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