Automated laser welding is a cutting-edge manufacturing process that merges the precision of laser technology with the consistency and speed of automation.
At its core, it’s the use of a laser beam (typically guided by a scanning optic, robotic, or gantry systems) to fuse materials in a controlled, noncontact manner.
The “automation” component refers to the integration of laser sources, optics, motion systems, part-positioning devices, and real-time monitoring. These are all orchestrated through software and feedback systems to produce high-quality welds at mass-production scales.
In this article, we will review the components of automated laser systems, the benefits of automated laser welding in different industries, and its various applications.
Table of Contents
In recent years, fiber lasers have become the most common type of laser due to their compact size, electrical efficiency, and beam stability. Power levels range from a few hundred watts for microwelding to tens of kilowatts for structural welds.
Other lasers are used in niche cases, such as CO₂ lasers for plastics and nonmetals, Nd:YAG for reflective materials, and green or blue lasers for copper and aluminum, where absorption of infrared light is poor.
Laser power, beam shaping, and optics focusing determine penetration depth, width, speed and quality.
Small spot sizes create fine keyholes, while defocused beams can be used for conduction welding of thin sheets (learn the difference between keyhole vs. conduction here).
Optical configurations include the following:
There are three main types of laser head mounting, which are described below:
A weld monitoring system is essential if you want to automate welding. These systems use feedback from sensors, cameras, and other devices during the welding process to examine the quality of the welds. Automatically detecting defective welds is a big advantage in production as it prevents having to perform manual tests to control quality.
Laser welding systems consist of three main real-time weld monitoring apparatus:
Lasers can pose severe eye and skin hazards. Automated systems are typically enclosed in Class-1 housings to ensure they are safe for operators without special eyewear.
These enclosures also control fume extraction and integrate safety interlocks to comply with occupational regulations.
Vision systems serve two roles:
Clamping ensures there are no gaps between parts. Even a small gap can cause porosity or weak joints. Advanced clamping systems apply uniform pressure and sometimes use adaptive fixtures that accommodate part variation.
In battery welding, for instance, clamps maintain close contact between busbars and cells to ensure a close to zero-gap prior to the welding to ensure quality welds.
By using multiple robots, this laser welding machine maximizes the laser’s uptime by ensuring that welding does not have to wait after clamping.
Together, these components create a system that offers high repeatability, minimal thermal distortion, and robust welds. Continuous improvements in optics, sensing, and AI-driven feedback have made these systems more autonomous and reliable.
Remote laser welding is when the laser head is physically separated from the laser source. Remote systems can direct the laser beam very quickly using mirrors called galvanometers. They can also be equipped with fast-focusing optics to quickly adapt for surfaces with varying heights.
Remote laser heads can either be static and join components that are within their line of sight. Or, they can be mounted on robots, gantries, or CNCs to achieve maximum flexibility and access difficult areas.
Fiber lasers are ideal for remote laser welding due to their compact size and good beam quality that is maintained over long distances.
Laser welding plays a vital role in advanced energy and mobility systems:
In medical device production, laser welding is indispensable for combining delicate, miniature components with high cleanability and strict regulatory compliance.
Laser welding of catheters, guidewires, pacemaker cases, and other small-diameter assemblies provides strength, sterility, and desirable cosmetic appeal. These systems often include integrated tooling, vision, and software for validation and traceability, maintaining process stability to support stringent FDA/ISO regulatory frameworks. Applications of welding in the medical device manufacturing industry include:
If you are looking for an automated welding solution, we can help you:
Keven is the product line manager for Laserax’s battery welding solutions. He has a strong background in electrical engineering, especially in PLC programming, electrical design, and vision systems. He is often involved in evaluating customer needs to offer adapted industrial solutions.
Laser welding is a highly precise and efficient welding technology used across various industries including automotive, aerospace, and medical manufacturing. It offers deep penetration, high welding speeds, and minimal thermal distortion, making it an ideal choice for applications requiring accuracy, speed and repeatability.
The integrity of a weld is highly dependent on surface preparation. Aluminum has a natural tendency to form oxide and even a thin layer can lead to weld defects. Oxide and potential contamination from oils, lubricants, paints, and particulate matter can create bubbles of air trapped inside the materials, impacting the bonding process.
Laser beam welding (LBW) is a precise and efficient method used to join materials through the use of a laser beam. It is known for its accuracy, speed, and ability to work on small, delicate components, making it ideal for industries like electronics, batteries, automotive, and aerospace.
