Tooling & Mold Engineering
Cold Plate FSW & Laser Welding Fixtures — Precision Fixturing for Thermal Assemblies
We design and manufacture fixturing and tooling for friction stir welding (FSW) and laser welding of cold plates and thermal assemblies used in power electronics, EV inverters and high‑power modules. Our fixtures control part registration, clamping, thermal sinks, reaction forces and sensor feedback for repeatable, high‑quality welds.
- FSW fixtures: torque reaction, robust backing, sacrificial supports and Z‑axis control
- Laser welding fixtures: precise datum registration, beam access, gas shrouding and active cooling
- Robotic/automation interfaces, quick‑change pallets, sensors and traceable process records
FSW Fixtures — Torque Reaction & Backing
Laser Welding Fixtures — Beam Access & Gas Shroud
Robotic Cells & Quick‑Change Pallets
Friction Stir Welding (FSW) Fixtures
FSW fixtures are built to withstand significant axial and rotational forces while maintaining precise part registration. Key design features include clamping that prevents slippage, robust backing plates (sacrificial or replaceable), Z‑axis positioning, and easy access for tool change and maintenance.
Critical fixture elements
Rigid datum locators and preload clamps to maintain joint gap and surface flatness. Sacrificial backing plates or hardened inserts to protect fixture from tool wear. Z‑axis control with high‑accuracy encoders and force sensors for plunge depth and spindle load feedback. Integrated coolant channels or thermal mass to control heat build‑up near the tool
Process & QC integration
We integrate torque / spindle load monitoring, axial force sensing and thermocouples for real‑time process control. Data logging links each weld to part serials and operator IDs for traceability.
Laser Welding Fixtures
Laser welding fixtures prioritize precise part datums, unobstructed beam paths and gas-shrouding/nozzle integration. Fixtures minimize gap variation and provide active cooling and heat sinking to limit distortion during high‑energy welds.
Key design points
- Precision locators and fine‑adjustment micro‑clamps to control gap & alignment
- Beam access windows, mirror/nozzle clearance and fiber‑optic routing provisions
- Shielding gas manifold integration with adjustable flow to control oxide and porosity
- Active cooling (water channels or thermal plates) to extract heat from weld zones
Thermal Management & Distortion Control
Control of heat is essential for cold‑plate integrity. Fixture strategies include distributed thermal mass, dedicated water cooling channels, staged weld sequences to balance heat input, and pre/post‑weld stabilization. Thermal finite element analysis (FEA) and trial mapping guide fixture cooling design and weld sequencing.
Methods
- Active water cooling channels in fixture plates and contact pads
- Thermal spreader plates to distribute heat across a larger mass
- Staged weld patterns and dwell times to minimize asymmetric heating
- Pre‑heat or post‑heat as part of process where metallurgical needs dictate
Clamping, Registration & Quick‑Change Pallets
Reliable clamping preserves joint geometry during welding and enables repeatable cycle times. We design kinematic datums, vacuum or mechanical clamps, and quick‑change pallet systems to speed changeovers while ensuring accurate repositioning within microns.
Options
- Hydraulic or pneumatic clamps with force feedback
- Mechanical cam clamps for quick engage/disengage in automated cells
- Precision dowel and tapered pin datums for pallet repeatability
- Custom soft‑contact pads where surface protection is required
Fixture Materials & Construction
Fixture materials are chosen to balance rigidity, thermal conductivity and wear resistance. Typical choices: hardened steels or tool steels for contact faces, copper or copper‑alloys for thermal spreaders, aluminum for light structural pallets, and replaceable hardened inserts at wear zones.
Hardened tool steel
Wear resistant contact surfaces and clamping faces
Copper alloys
High thermal conductivity for heat extraction
Aluminum tooling bodies
Lightweight pallet structures with machined datum features
Ceramic / composite pads
Where electrical isolation or thermal barrier needed
Sensor Integration & Process Feedback
Fixtures routinely include sensors for process control and traceability: thermocouples, IR temperature sensors, force/torque sensors, displacement probes, and fiber optic weld seam monitors. Real‑time data feeds to SPC and MES systems enable automated accept/reject decisions and long‑term process improvement.
Typical sensors
- Axial force and torque sensors (FSW spindle feedback)
- Thermocouples and IR pyrometers for weld zone temperature
- Laser seam trackers and seam finders
- Contactless displacement sensors for gap monitoring
Robotic Integration & Safety
Fixtures are designed for robotic cells with quick‑change pallets, part kitting, vision alignment features and safety interlocks. We provide end‑effector interfaces and collaborate on cell layout, cycle timing and guarded access to meet production throughput and safety standards.
Integration deliverables
- Pallet and interface drawings for robotic grippers
- Cycle timing analysis and takt optimization
- Safety interlocks, light curtains and E‑stop integration
Tryout, Qualification & Quality Gates
Fixture tryout includes alignment verification, clamp force validation, weld parameter optimization and distortion measurement. We deliver first article welds, CMM inspection of critical datums, non‑destructive weld evaluation (visual/X‑ray/CT where applicable), and documented process windows for production release.
Tryout deliverables
- First article weld assemblies with dimensional reports
- Weld energy/force vs quality mapping and recommended process window
- Sensor calibration records and control charts
- Fixture acceptance checklist and maintenance schedule
Maintenance, Spares & Lifecycle Support
We supply recommended PM intervals, spare inserts/backing plates, and refurbishment services for wear zones. For critical lines we offer SLA options for rapid replacement, onsite support during ramp, and tool storage with controlled humidity to prevent corrosion.
| Item | Typical Range / Value | Notes |
|---|---|---|
| Fixture flatness | ≤ 0.05 mm across critical datum | Depends on weld seam length and optical requirements |
| Datum repeatability (pallet) | ≤ 0.02–0.05 mm | Important for laser seam accuracy |
| Clamp force | Programmable 0—50 kN | Hydraulic/pneumatic options with feedback |
| Cooling capacity | Up to 5 kW+ localized | Based on weld energy and cycle time |
Representative Projects
FSW Fixture for EV Inverter Cold Plate
Custom fixture with replaceable backing inserts, force/torque sensing, active water cooling and quick‑change pallet. Enabled automated single‑sided FSW with <0.1 mm flatness across sealing faces and documented Cpk improvements on joint quality.
Laser Weld Cell for Cold Plate Seam
Fixture with precision dowel datums, micro‑clamps, gas shroud manifold and IR temperature monitoring. Achieved leak‑tight seams with minimal post‑machining and integrated MES traceability for each unit.
Frequently Asked Questions
Which welding method is better for cold plates — FSW or laser?
FSW is excellent for high‑integrity, low‑porosity joints in aluminum with minimal melt‑zone metallurgy; good for thick sections. Laser welding is faster for thin seams, offers narrow HAZ and minimal distortion when well controlled. Choice depends on geometry, material thickness, leak requirements and throughput.
How do fixtures handle different part variants?
We design modular fixtures with replaceable inserts, adjustable locators and pallet families. Quick‑change tooling reduces changeover time and enables single cell support for multiple variants.
Do you provide on‑site commissioning and operator training?
Yes — we support fixture installation, process qualification, on‑site commissioning, train operators and provide run‑rates, maintenance procedures and troubleshooting support during ramp.
How do you validate weld leak tightness?
We perform helium leak tests, pressure decay, vacuum, and where applicable CT/X‑ray inspection. Acceptance criteria are defined by functional requirements and industry standards; test reports are delivered with each lot.
Start Your Welding Fixture Project
Upload your cold plate CAD, seam path, material(s) and target throughput. We’ll return a fixturing recommendation, estimated lead time and a proposal for sensor/automation integration — typically within 24 business hours.
