Driven by the dual growth of 5G communications and the explosion of AI computing power, SFP and QSFP optical modules, as core data transmission hubs, are evolving towards higher density, higher speed, and higher reliability. The precision and stability of their welding processes directly determine the transmission efficiency and lifespan of communication systems. Guangdong Fly Laser Intelligent Equipment Co., Ltd., deeply engaged in the field of precision laser welding, is reshaping SFP/QSFP manufacturing standards with breakthrough technological solutions, injecting high-quality development momentum into the optical module industry.
As a staple module for medium- and low-speed access scenarios, the sealing welds between the SFP metal cage and shield must balance structural robustness and signal interference resistance. QSFP modules, designed for high-speed backbone transmission, integrate more channels and precision components, placing even stricter demands on micron-level welding positioning and minimal thermal damage. Traditional welding techniques often suffer from pain points such as large heat-affected zones, poor solder joint consistency, and insufficient airtightness, becoming bottlenecks hindering the performance upgrade of optical modules. Fly Laser's specifically developed laser welding system precisely meets the manufacturing requirements of both types of modules.
Core technological breakthroughs and the establishment of a barrier to welding precision are Fly Laser's significant advantages. The 515nm wavelength green laser achieves an absorption rate exceeding 40% for the copper alloy commonly used in SFP/QSFP applications, over eight times higher than traditional infrared lasers. This fundamentally reduces weld spatter and porosity, while improving penetration stability by 30%. Combined with a 50-micron transmission fiber core diameter and excellent beam quality of 2mm·mrad, it enables micron-level welding with pads as small as 0.2mm and pitches as small as 0.25mm. This perfectly meets the high-density pin connections of QSFP modules, completely eliminating defects such as solder bridging and cold solder joints. For sealing SFP cages, the laser beam precisely forms continuous welds, achieving 300% greater airtightness than traditional processes, and achieving zero-leakage packaging.
Low thermal damage control, safeguarding the performance of precision components, is a key competitive advantage of the Fly laser solution. Components such as the optical chip and lens integrated within SFP/QSFP are extremely temperature-sensitive, and the extensive heat conduction of traditional welding can easily lead to component failure. Fly Laser utilizes a real-time power closed-loop feedback control system to maintain energy output stability within ±1%. Laser energy is precisely focused on the solder joint, minimizing the heat-affected zone. This non-contact processing method prevents mechanical stress from damaging delicate components like FPCs, ensuring precise optical path alignment after welding and uncompromising the module's photoelectric conversion efficiency.
Full-process intelligent control maximizes both efficiency and quality, providing a solid foundation for mass production. Feilei Laser's welding system integrates machine vision and AI algorithms to automatically manage the entire process, from pre-weld position capture and correction, to in-weld parameter adjustment, and post-weld defect detection. The welding process requires no flux, resulting in smooth, full solder joints and no subsequent polishing, reducing environmental pollution while reducing production steps by over 30%. In mass production applications at companies such as Dingtong and Luxshare, this system has achieved a remarkable 99.5% SFP/QSFP soldering yield and increased daily production capacity by 50%, fully demonstrating its cost-effectiveness.
From data centers to 5G base stations, performance upgrades for optical modules are essential for breakthroughs in manufacturing technology. Guangdong Fly Laser leverages its core green laser technology, supported by precision control and intelligent integration, to provide a one-stop solution for SFP/QSFP module welding, offering high precision, low heat loss, and high efficiency. In the rapidly developing optical communications industry, Feilai Laser is leveraging technological innovation to help companies overcome manufacturing bottlenecks and safeguard high-speed information transmission in the digital age.
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