Design and Prototypes

Weld Design

Carrs advise customers free of charge on weld preparations and provide ideas on how best to make things easy to weld. Making components and assemblies easy to weld translates into consistent and superlative quality results.

Welding is often the last (but critical) process to complete a component and considerable value may have been added by this stage. Please don’t leave it to the last moment to talk to us about it – you will be surprised at what is possible.

Carrs have been welding for two decades; more than sufficient time to teach us how metal is best prepared for welding. In order to streamline your production and achieve best results at minimal cost it is important in the initial stages of a project to design with laser welding in mind.

The main considerations for welds are:

  • Material – select a compatible grade which will also not crack or emit spatter
  • Joint configuration – consider optimum design with minimal gaps requiring filling
  • Access to weld – allow sufficient access for laser beam to complete weld without hindrance
  • Access for effective shielding gas is also an important consideration
  • Testing – what weld characteristics are crucial and what level of testing is required? Visual, leak test, dye penetrant, vacuum/helium or other test rĂ©gimes

Micro Analysis

Micro analysis entails laboratory assessment of welds and Heat Affected Zones (HAZ) which is important when qualifying a new weld parameter.

Carrs calculate the heat input for every application to ensure the assembly is not heated any more than necessary. This determines optimum long term conditions for the welded parts in their designated operating environment.

Visual inspection of the weld and its colour provide a basic assessment, but scrutinizing a cross section at 200-400x optical magnification will reveal possible failure modes and provide the detailed information necessary to fine tune weld parameters.

Critical elements of any weld are the fusion zone, defects, possible crack sites and the heat affected zone (HAZ). The structure of the material is revealed when looking at a micro section, where the heat input and the cooling rate are all important factors.

Micro analysis is more important in exotic materials, where corrosion qualities may be impaired if heat input is excessive and could result in premature failure of an assembly.


Carrs are able to weld prototypes of any metal design. This might for example be a car component where prototype or pre-production work is needed prior to mass production, or where only a small batch is required. At the other end of the spectrum it could be a new sensor design where conceptual testing needs to be carried out. We are approached on a daily basis with new application challenges and rarely fail to find solutions for them.

We are a highly flexible company, focussed on laser welding for a multitude of applications in diverse sectors and can bring this experience to help you develop your product (free of charge if you entrust us with the production work).

Irrespective of the production volume, such testing and trials enable Carrs accurately to bid for production welding.