Precision optical repair shops that focus on timely, high-quality repairs of eyeglass frames and accessories now have access to many new technologies. These tech advancements allow them to better serve their customers. One of the fastest-growing technologies among them is the use of laser welding eyeglass frame repair instead of traditional solder and fusion welding repair techniques.
Laser welding uses pinpoint accuracy and very little heat dispersion, which protects delicate parts. Eyeglass frame repair with laser welding is the best choice for opticians and wearers alike. That’s because it can work with many metals and do complex repairs. It promises that beloved eyewear will work better and last longer.
To give you a better idea of how it’s done, in this article, we will discuss how the laser welding system exactly works to minimize the difficulty of frame fixes. We will also look into the methods of laser welding that are used to repair eyeglass frames. Keep reading to explore more.
Why Opt for Laser Welding Eyeglass Frame Repair?
Using laser welding for eyeglass frame repair has many advantages. The speed, efficiency, and longevity of laser welding greatly enhance the repair process. Instead of using a different metal to fuse the pieces together, a very intense laser beam melts and fuses them. Pulses of this laser light, which only last milliseconds, fix the damage precisely.
On top of that, due to the extremely short heating and cooling cycles, there is almost no discoloration left after welding. The repaired glasses can be worn for years to come without anyone ever suspecting a thing.
For all of the reasons mentioned above, thousands of people choose laser welding to repair their damaged metal-framed spectacles.
How The Laser Welding System Works for Optical Repair
The “free-moving” concept of laser welding systems is primarily used to repair optics. This idea changed the way eyeglass repairs were done. It eliminates the need for expensive fixtures and makes it easier to assemble and repair items.
The free-moving method uses a steady pulse of infrared light pointed through the crosshairs of a microscope. The pulse can be changed in size and power. That’s how precise and localized heating happens. Hence, when operators weld small areas with pinpoint accuracy, they can hold or repair items with their fingers without injuring themselves. The deflected pulses only hurt like a pin-prick. However, it is very important to make sure from the manufacturer that the machine is FDA-approved (Food and Drug Administration) for safety. Fully enclosed systems are safe to use because they meet Class 1 safety standards.
When it comes to controls, the operator of a laser welding system changes the beam diameter, power level, and pulse length based on the type of metal and joint. A stereo microscope with crosshairs helps precisely line up the weld, and a foot pedal turns on the laser. Cover gas, usually, Argon, is also used in many systems to make sure the weld is clean and does not get messed up or discolored.
Two Basic Eyeglass Frame Repair Methods with Laser Welding
Repairing eyeglasses can be done in two main ways, depending on the densities of the metals used. You can find them below:
Method 1 – Direct Welding
As the name implies, this method does not involve applying filler material to the contact points of the eyeglass frames. This is how the process takes shape:
- First, the eyeglasses are prepared by lightly filing the broken area to ensure a flush fit. The welding machine is also configured to produce a proper keyhole weld.
- After that, the frames are tacked together twice or three times to make sure they are straight.
- Once the frames are straight, the 50% overlap method is used to run a welding bead all the way around the broken part.
- Now, the right filler wire for the plating color is used. For example, 10K YG (yellow gold) filler is used for gold plating, and 10K WG (white gold), or silver solder filler, is used for silver plating. The parameter settings for the filler wire must be the same as those used for the keyhole weld. The voltage, milliseconds, or beam diameter must be changed if the settings are too strong or too weak.
- Lastly, the beam diameter and hertz are raised to hammer the filler material smoothly. As the final touch, the frames are put through a test to see how well they can handle normal pressure.
Method 2 – Capping
This method requires some additional steps before proceeding to the direct welding method. Here’s how it’s done:
- Before starting this method, the glasses are prepared by getting rid of any filler material and/or brittle alloy and making sure the joints fit flush again. Plus, the machine is set up to do a good keyhole weld.
- Then, filler material is put on both of the eyeglass frames’ contact points. When it is done, there should be a small “mound” or “cap” of filler material on each side.
- Next, the eyeglasses are brought back to the bench and re-prepped by lightly filing the “mounds” of filler material until the contact points once again fit flush. The filler material is taken away just enough to make sure the pieces fit together smoothly.
- After making the keyhole weld, the steps in Method 1 are carried out.
Examples of Laser Welding Technology’s Impact on Eyewear Frame Repair
Laser welding has improved manufacturing as a whole. However, this technology has been truly revolutionary in some cases when it comes to fixing broken eyeglass frames. This is how:
Metal Frame Repairs
Most laser welding is done through the lens of a microscope to assure the pinpoint precision of the laser. Nowadays, a skilled laser welder can fix almost any metal frame for glasses or sunglasses, even ones made of rare or flexible metals like beryllium, nickel, and alloys. A laser’s pinpoint accuracy makes for the cleanest and least noticeable weld possible, as well as an almost seamless finish.
Dealing with Titanium Frames
Titanium frames are known for being strong and light, but they can still break, bend, and snap apart. Professionals who are skilled at their craft can use lasers to join pieces of titanium together. They can also mix metals like nickel and beryllium to make alloyed flexible metals.
FAQs
Q. What Makes Laser Repair Different from Traditional Eyeglass Repair Methods?
Ans: Laser eyeglass repair uses the latest laser welding technology that works at low temperatures. Unlike traditional methods, which often involve soldering, laser repair precisely covers breaks without damaging the frame’s plating or coating. It keeps the frame’s finish and does not leave any marks.
Q. Can All Types of Eyeglass Frames be Repaired with the Laser Welding Method?
Ans: Of course! Laser welding can be used to fix many types of eyeglass frames, such as titanium, stainless steel, and other rare metal alloys. It lets you achieve a precise bond without using too much heat, so the frame finishes stay in good shape.
Conclusion
Laser technology is really impressive at fixing many kinds of metals, including titanium, with a smooth, long-lasting finish. It has also completely changed how eyewear repairs are done. Laser welding uses intense laser pulses to carefully join frames together. This keeps discoloration to a minimum. The free-moving concept of this welding technique allows for precise, safe repairs without fixtures.
To maintain the quality of the weld, operators use Argon gas to change the beam diameter, power, and pulse length. They primarily use two methods for frame repairs: direct welding and capping, which adapt to different metal densities.
However, regardless of the method used for the repair, an excellent product requires a high-quality laser welding machine. This is what Fiber Laser Welder strives to guarantee. Our goal is to use advanced machinery to transform the welding sector. Contact us today to get your desired laser welding machine.