New Product Development

Welding Process Development

microJOINING SOLUTIONS designs weldability into your new product by preventing costly design mistakes.

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Surface Plot of Time vs Slope

Designing for Weldability

At microJOINING SOLUTIONS, we specialize in welding process development, helping our clients integrate “weldability” into their new products. Many welding mistakes originate in the design stage, making it crucial to consider key weldability components, such as:

Material Selection: Choosing the appropriate base and plating materials.

Part Geometry: Balancing thermal loading between components for optimal performance.

Accessibility: Ensuring adequate access for resistance welding electrodes or laser beam cones.

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Interaction Plot

Optimizing Your Welding Process

Once the design phase is complete, microJOINING SOLUTIONS partners with clients to enhance their welding processes using the Design of Experiment (DoE) methodology, backed by years of hands-on experience in both high and low-volume production. Our process includes:

Defining Weld Quality: Establishing clear criteria for desired outcomes.

Identifying Input Factors: Pinpointing controllable variables that affect weld quality.

Mapping Output Responses: Relating output results to the defined weld quality.

Conducting DoE: Testing with production parts and equipment to ensure real-world applicability.

Parameter Optimization: Refining welding parameters for best results.

Confirmation Runs: Establishing Cpk or Six Sigma metrics to validate process capability.

Setting Process Limits: Defining boundaries to maintain quality consistency.