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In the dynamic world of metal joining technologies, laser welding has emerged as a game-changer, offering unprecedented precision and efficiency. One particularly intriguing application involves welding thin-gauge copper using IPG LightWELD technology and helium gas. In this blog, we’ll explore the intricacies of this innovative process, highlighting its advantages and showcasing the remarkable capabilities of IPG’s cutting-edge technology.

laser welding line card

Understanding the Basics:

Before delving into the specifics, it’s essential to grasp the fundamentals of laser welding. Unlike traditional welding methods, laser welding employs a highly focused laser beam to melt and fuse metals. This focused energy allows for precise control, making it ideal for intricate applications and thin materials.

IPG LightWELD Technology:

At the forefront of laser welding technology is IPG Photonics, a pioneer in fiber laser solutions. The LightWELD series from IPG is renowned for its exceptional beam quality, high peak power, and versatility. These attributes make it particularly well-suited for welding thin-gauge copper with unparalleled precision.

Helium Gas: The Secret Weapon

In the realm of laser welding, the choice of shielding gas is crucial. Helium, with its unique properties, emerges as a secret weapon in achieving optimal results when welding copper. Being an inert gas, helium minimizes oxidation during the welding process, preventing the formation of undesirable oxides on the copper surface. This is especially critical when working with thin-gauge copper, where precision and cleanliness are paramount.

Advantages of Laser Welding with IPG LightWELD and Helium:

  1. Precision beyond Par: The combination of IPG LightWELD technology and helium gas ensures pinpoint accuracy, allowing for intricate welds in thin-gauge copper without compromising structural integrity.
  2. Reduced Heat Affected Zone (HAZ): Laser welding minimizes the heat affected zone, preserving the material’s properties. This is particularly advantageous when working with thin copper, as it helps prevent distortion and maintains the material’s original form.
  3. Enhanced Productivity: The speed and efficiency of laser welding significantly contribute to increased productivity. IPG LightWELD, in tandem with helium gas, facilitates rapid, clean, and precise welds, making it an ideal choice for industrial applications.
  4. Minimized Post-Weld Cleanup: Helium’s inert nature reduces the need for extensive post-weld cleanup, saving both time and resources. This is a significant advantage, especially in industries where cleanliness is crucial.

Laser welding copper

Case Studies and Real-world Applications:

Bruno Carvalho our laser welding specialist at Spark & Co said;  ”In recent tests using helium as a shielding gas along LBW, I’ve seen an impressive 50% boost in penetration when welding a copper plate to stainless steel. What’s even more exciting is the noticeable improvement in the laser’s penetration capacity when welding two copper plates together. Helium has a high thermal conductivity, which means it can transfer heat away from the weld more efficiently. This can help prevent overheating and produce a more controlled weld. These results highlight the real impact of helium on pushing the boundaries of laser welding, opening up new possibilities for efficiency and performance.”

welding stainless and copper with Ilaser welding

IPG LightWELD technology and helium gas has made a tangible impact on industries such as electronics, automotive, or aerospace. Highlight specific projects, emphasizing the unique challenges overcome and the exceptional results achieved.

“Get ready to dive into the futuristic world of laser beam welding, where copper takes center stage! Said Bruno ; ‘’ Welding copper, especially with those beefy plate thicknesses and leisurely welding speeds, can be like navigating a tricky obstacle course with potential pitfalls at every turn. But fear not! We’ve got a game-changer – introducing the IPG Laser Welding.’’

By dialing down, the ambient pressure, we’re not just reducing stress; Making it possible to tackle those challenging copper welds with finesse. With speeds below 2 m/min, this process lets us dance through the welding routine, achieving a depth of penetration that’ll leave you awestruck – and all with surprisingly low laser power.

So buckle up for a wild ride through the cosmos of high-quality copper welding. IPG LightWELD is here to make welding fun, efficient, and downright impressive. Let’s break through the barriers and redefine what’s possible in the world of laser welding – because with IPG LightWELD , the sky’s the limit!”


As we navigate the ever-evolving landscape of welding technologies, the synergy between IPG LightWELD and helium gas in laser welding thin-gauge copper stands out as a testament to innovation. The precision, speed, and efficiency offered by this combination open new possibilities across various industries, promising a future where intricate metal joining is not just a necessity but an art perfected by cutting-edge technology.

Her is also a great article about how lower pressure increases the quality of the copper weld .