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The latest developments in the use of lasers for welding plastics are reviewed. Lasers were demonstrated as being suitable for welding plastics in 1970. However, it is only now that they are finding wide application following technical developments in transmission laser welding and ClearWeld™, and the availability of small, economic diode laser systems.

High‐powered diode lasers are becoming increasingly used in manufacturing for transmission welding of thermoplastic materials. This process can replace many of the traditional techniques such as ultrasonic welding. Benefits include being a non‐contact process that can encapsulate sensitive electronic housings without damage. This is described in an electronic throttle assembly case study.

This paper focuses on some of the presentations given at a technical workshop on “Laser processing of polymer‐based materials”, organised by Association of Industrial Laser Users. Applications in cutting and welding are discussed and specifically how different combinations of polymer materials and laser types produce different results. Applications are described that include pre‐weakening of car trims for integrated airbags and “on the fly” scribing of web materials used in packaging. In several of these applications, robots play an important role in manipulating the laser beam.

Trials using high powered laser arrays recently available, have shown that a range of joining and surface treatment processes are possible. These range from transmission welding of polymeric materials to surface hardening, soldering and welding of steels.