Blind Microwelding: Tight-Spot Microwelding Examples 

At Percussion Welder, we are no strangers to tackling complex microwelding challenges. This week, we’re excited to share two extraordinary examples of how our Percussion Welder rose to the occasion and delivered effective solutions for seemingly impossible microwelding scenarios. Whether it's welding through blind spots or overcoming difficult angles, our microwelding technology has proven itself once again.

Example 1: Medical Device Microwelding

The Challenge:
A medical device manufacturer approached us with a problem that many thought couldn’t be solved. The task? They needed to attach a 30-gauge stranded copper lead wire (stripped length of 50 thousandths of an inch) to a stainless steel plate that was hidden beneath a 100-thousandths of an inch layer of porcelain laminate. The wire had to be welded through a tiny hole in the porcelain, making this a completely blind weld.

• Laser welding wasn’t an option because precise direction of the laser through such a tiny hole blindly was impossible.
• Resistance welding was ruled out because the fragile wire lacked the columnar strength needed to withstand the pressure required for a proper weld.

Our Solution:
The Percussion Welder was used for this unique challenge. Unlike laser or resistance welding, the Percussion Welder requires only minimal pressure, allowing the materials to lightly touch without being damaged. We engineered the weld so that:

• The copper wire was securely attached to the stainless steel plate without breaking.
• There was no measurable reduction in electrical resistance.
• The stainless steel plate remained free of discoloration, ensuring the integrity of the medical device.

In the end, this delicate and complicated weld was a success.

Example 2: Automotive Electronics Microwelding

The Challenge:
In this case, we were approached with a challenge that seemed so out of the realm of possibility that many thought it was simply unachievable. The task? To weld a solid copper wire to the center core of a coax cable, inside a housing with a 90-degree elbow, right at the bend of the housing.

This made it a completely blind weld with almost no room to maneuver traditional welding tools. Needless to say, it was a microwelding challenge unlike any other.

Our Solution:
While the details of how we engineered this solution are intricate and highly specialized, we won’t bog you down with technicalities. The bottom line? We succeeded. Using the Percussion Welder, we were able to:

• Weld the solid copper wire and the coax cable core precisely at the elbow without damaging either.

The result? Another “impossible” microwelding challenge solved!

Percussion Welder for Blind and Tight-Spot Microwelding

The Percussion Welder has been used for minimal-pressure welds, blind welding, and welds at difficult angles.

Have a Microwelding Challenge?

If you’re facing a microwelding challenge—no matter how complex or “impossible” it may seem—we invite you to reach out to us. Our team thrives on solving tough problems, and with the Percussion Welder in our toolkit, we can tell you whether it is a fit.

• 📞 Call us at 303-536-7838
• 📧 Email: sales@percussionwelder.com
• 📅 Or schedule a Zoom consultation

You never know what’s possible until you give us a try!

Conclusion

At Percussion Welder, we take pride in solving microwelding challenges that others deem impossible. Whether it’s tight spaces, blind spots, or fragile materials, we can tell you whether the Percussion Welder is a fit for your application. Let us show you what the Percussion Welder can do!