With the deployment of 5G base stations on a million-scale scale, new energy vehicles equipped with LiDAR systems on the road, and AI data centers striving for 448Gb/s transmission rates, laser connectors, as "connection hubs," are experiencing explosive demand. The Chinese laser connector market is projected to exceed 2.27 billion yuan by 2025, with the communications, automotive, and industrial sectors contributing over 90% of the demand. However, high-end connector manufacturing has long faced pain points such as difficulties in copper material processing, high signal loss, and weak environmental adaptability. Guangdong Fly Laser Intelligent Equipment Co., Ltd., with eighteen years of accumulated laser technology experience, has provided a disruptive solution.

Industry Pain Points Become Prominent, Connector Manufacturing Urgently Needs Technological Breakthroughs

Connectors, acting as the "blood vessels of electronic devices," directly determine system stability. However, in high-end manufacturing scenarios, three core pain points have long constrained industry development:

**Material Processing Bottleneck:** Copper alloys, a core material for high-speed connectors, have an absorption rate of less than 5% for traditional infrared lasers, leading to severe welding spatter and unstable molten pools, directly impacting signal transmission quality. The 800V platform upgrade for high-voltage connectors in new energy vehicles further demands micron-level welding precision.

**Multi-Scenario Adaptability Challenges:** From the high-cleanliness environments of data centers to the vibration and dusty environments of automotive chassis, from the precision transmission of medical equipment to the continuous operation of industrial robots, different scenarios present vastly different requirements for connector temperature resistance, waterproofing, and anti-interference performance.

**Efficiency-Cost Contradiction:** Traditional processing methods require multiple steps, resulting in a rework rate as high as 15%. The high-end market has long been monopolized by imported equipment, with a domestic production rate of less than 30%, leading to persistently high manufacturing costs.

Behind these pain points lies the ultimate test of laser processing technology—the emergence of Fly Laser is reshaping this landscape.

Three Core Breakthroughs: Reconstructing Manufacturing Logic with Laser Technology

Fly Laser has been deeply involved in the field of precision laser processing for many years, building a four-in-one technology system of "optics-mechanics-electronics-intelligence". Its core laser processing solutions have become standard equipment for leading connector companies such as Dingtong and Luxshare. Key breakthroughs are reflected in three dimensions:

1. Laser Technology: Overcoming Global Challenges in Copper Processing

Addressing the pain points of copper alloy processing, a core component of connectors, Fly Laser's independently developed laser has achieved revolutionary breakthroughs:

Absorption Rate Increased by 8 Times: Utilizing 515nm wavelength green light, the absorption rate of copper is increased from 5% to over 40%, significantly reducing the risk of laser reflection and improving welding penetration stability by 30%.

Dual Extremes in Power and Precision: 3kW continuous output power meets the needs of high-speed mass production. Combined with a 50-micron transmission fiber core diameter and beam quality optimized to 2mm·mrad, it achieves 0.01mm-level precision welding, perfectly adapting to the processing of miniature connectors such as Type-C and HDMI 2.1.

Intelligent Closed-Loop Control: All models come standard with a real-time power feedback system, ensuring stable energy output error is controlled within ±1%. Combined with AI algorithms, it achieves full-process monitoring from pre-welding positioning and correction to post-welding defect detection, reducing the welding defect rate to below 0.3%.

2. Full-Scenario Adaptability: Covering the Entire Connector Manufacturing Lifecycle

From prototype development to mass production, Feilai Laser has built a complete connector manufacturing solution:

Precision Welding Matrix: From fiber optic laser welding machines to high-speed galvanometer laser welding machines, it can perform various processes such as spot welding, seam welding, and lap welding, adapting to different welding needs from automotive high-voltage terminals to communication RF connectors. The fatigue strength of the solder joints is improved by 40% compared to traditional processes.

High-Efficiency Stripping Technology: The UV laser wire stripper achieves burr-free cutting of the aluminum foil shielding layer of high-frequency cables such as HDMI 2.1 and USB 4, avoiding damage to the core wire. The processing efficiency is 3 times higher than that of tool-based methods.

Customized Flexible Production: Supports 0.4mm micro-pitch connector processing, enabling rapid switching between different product models to meet diverse, small-batch customization needs, reducing equipment changeover time to less than 15 minutes.

3. Extreme Environment Reliability: Giving Connectors a "Durable Body"

Through collaborative innovation in materials processing and laser technology, Feilai Solutions' connectors can easily withstand various scenarios:

Upgraded Environmental Tolerance: Welded joints pass high and low temperature cycling tests from -55℃ to 200℃, achieving an IP67 waterproof rating and vibration resistance meeting IEC 60068-2-6 standards, making them suitable for harsh environments such as new energy vehicle chassis and industrial outdoor equipment.

Signal Integrity Guarantee: The homogeneous joints formed by laser welding reduce signal attenuation. In 5G communication 6GHz high-frequency transmission scenarios, insertion loss is controlled within 0.1dB, far exceeding the industry average.

Long-Term Stability: The laser achieves stable power output for over 10 years, and the processed connectors have a mating life of over 100,000 cycles, meeting the long lifecycle requirements of data centers, medical equipment, and other applications.

Deploying in Three Key Industry Sectors, Witnessing the Strength of Domestic Technology

Deploying in Three Key Industry Sectors, Witnessing the Strength of Domestic Technology

Leveraging its core technologies, Fly Laser's solutions have deeply penetrated the core application areas of connectors, becoming a key driver of industry upgrades:

Telecommunications: Facilitating "Ultra-High-Speed Interconnection" for Data Centers

Against the backdrop of explosive growth in AI computing power, Fly Laser's technology supports the mass production of 400G/800G optical module connectors. Its processed high-speed copper cable connectors can achieve a transmission rate of 448Gb/s-PAM4, meeting the expansion needs of ultra-large data centers such as ByteDance and Alibaba Cloud. A single production line has a daily capacity of 20,000 units, a 50% increase compared to traditional equipment.

Automotive: Empowering "Perceptive Interconnection" for Intelligent Driving

Addressing the connector needs of LiDAR and ADAS systems in new energy vehicles, Fly Laser's welding equipment achieves high-sealing processing of automotive connectors, achieving an IP68 waterproof rating and stable operation in environments ranging from -40℃ to 150℃. After adopting this solution, a leading automaker saw its LiDAR connector failure rate drop from 1.2% to 0.08%, and its per-vehicle manufacturing cost decrease by 18%.

Consumer Electronics: Unlocking "Precision Interconnection" for High-End Interfaces

In the processing of high-end connectors such as Type-C and Thunderbolt 4, Fly laser's UV laser marking machine achieves micron-level logo laser engraving, and its QCW laser welding machine completes 8-point welding between the fixing plate and the shell, increasing the connector's tensile strength to over 50N, passing the stringent certifications of brands like Apple and Huawei.

Eighteen Years of Accumulation: Forging the "Chinese Core" of Connector Manufacturing

Founded in 2008, Fly Laser is no longer simply an equipment supplier, but a deep participant in the connector industry:

Full Industry Chain Layout: A nearly 10,000-square-meter production base has been built in Dongguan, with a technical team of over 110 people. Domestically, it covers seven major regions including East and North China, and its overseas service network spans more than 30 countries and regions, enabling 24-hour rapid response.

Industry Ecosystem Collaboration: As a core supporting unit of the Shenzhen Connector Industry Association, it deeply participates in the formulation of industry standards, promoting the standardized application of laser processing technology in the connector field.

Continuous Technological Iteration: Investing 15% of its revenue in R&D annually, it has developed over 20 core patents for connector manufacturing, with technical indicators comparable to international giants such as Trumpf (Germany) and FANUC (Japan).

Conclusion: Connecting the Future with Light, Growing Together with Industry

“As "new infrastructure" and "intelligent manufacturing" deeply integrate, the value of connectors is no longer simply "connection," but rather a "fidelity guarantor" for data transmission and a "stabilizer" for equipment operation. With eighteen years of accumulated laser technology experience, Fly Laser is writing the "Chinese answer" to high-end connector manufacturing, from solving processing pain points to defining manufacturing standards, from serving leading enterprises to empowering industrial upgrading.

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