TRUMPF’s Brightline Scan Technology Enhances Precision and Tolerance Control in Laser Welding!

TRUMPF Inc. has introduced its Brightline Scan technology for the TruLaser Weld 5000 laser welding system, bringing a new level of precision, flexibility and process stability to high-performance laser welding applications. Designed to improve weld quality while enabling the processing of thicker materials, Brightline Scan leverages advanced optics and scanner-guided beam control to help fabricators achieve tighter tolerances and more reliable welding outcomes across a wide range of industries.

At the heart of this innovation is the combination of robotic motion with scanner-based laser guidance. Traditionally, welding robots dictate the movement of the laser beam through their articulated paths. With Brightline Scan, TRUMPF adds a second layer of control by using a laser scanner equipped with lightweight, high-speed mirrors capable of oscillating the beam at kilohertz frequencies. This technique allows the laser path to be supplemented with freely programmable beam movement in any direction, independent of the robot’s motion. As a result, the system dramatically enhances flexibility and enables heat conduction welding of sheet thicknesses from 0.12″ up to 0.24″, significantly expanding the types of parts that can be processed.

Brightline Scan enables operators to finely tailor the bonding surfaces of the welded components. Because the laser beam melts the material precisely at the defined scan pattern, manufacturers gain tighter control over weld geometry, penetration and seam consistency. TRUMPF notes that this capability not only produces higher-quality parts but also improves overall process reliability—an increasingly important requirement in industries where consistent weld integrity is essential.

The technology’s precision is made possible by TRUMPF’s PFO 20 programmable focusing optics, integrated directly into the robot’s welding head. This hybrid control approach—combining robot motion with scanner-guided laser tracking—provides a substantial improvement in robustness and adaptability, especially for complex geometries or parts requiring strict dimensional tolerances.

To support usability and faster production setup, TRUMPF provides TechSets, preconfigured parameter sets for common welding applications. In addition, Brightline Scan is fully compatible with TRUMPF’s TruTops Weld offline programming software. This allows operators to program new welding paths and scan strategies while the machine continues welding another part, minimizing downtime and improving workflow efficiency.

Brightline Scan proves particularly valuable in the manufacturing of products such as EV battery trays, electrical cabinets, and furniture components, where tight tolerances and consistent seam quality are critical. Its ability to handle sheet materials up to 0.24″ thick with high precision makes it an ideal solution for applications demanding both speed and accuracy.

With the introduction of Brightline Scan, TRUMPF continues to push the boundaries of laser welding technology—offering manufacturers a robust, high-precision tool that enhances productivity, expands application possibilities and delivers superior weld quality across a range of demanding fabrication environments.