Laser Welding Automation

Not at all. The LightWELD laser welding technology is easy to learn, regardless of your welding experience level. All LightWELD systems come pre-loaded with over 100 welding and cleaning parameters for common materials and thicknesses. You can also create your own recipes to adjust your travel speed and desired weld penetration.

The LightWELD Cobot System (LWCS) does not require operators to program with code (though that’s an option if desired). LWCS is typically taught by manually guiding the robotic arm through a welding or cleaning task. The arm can remember hundreds of tasks and will execute the steps and movements for a specific task whenever needed.

No, quite the opposite. Cobots are designed to work alongside humans and assist them in various tasks. The LightWELD Cobot system requires a skilled welder to teach it how to perform various welding tasks. Cobots are like any other tool: they help creators and craftsmen work faster and more efficiently, producing higher-quality finished products.

The LightWELD Cobot system is designed to help skilled welders be more productive. While the system can handle a wide range of welding and cleaning tasks, it is particularly suited for managing repetitive and less rewarding welding tasks. By working more efficiently with this type of welding, skilled welders can spend their time on more challenging and interesting welds. Additionally, the high repeatability and precision of LightWELD Cobot systems reduce the time welders need to spend on touch-ups and grinding.

Methods in all applications. However, laser welding offers several advantages over MIG & TIG welding:

• Welding speed up to 4 times faster
• Reduced heat-affected zone
• Increased precision and repeatability
• Minimal post-weld processing required
• Superior energy efficiency and reduced consumables
• Less experience required to achieve excellent welds
• Better results in vertical and overhead welds

LightWELD is a portable laser welding and cleaning technology designed to maximize weld quality and productivity. This advanced laser system enables fast, high-quality laser welds with minimal post-processing, making it ideal for various manufacturing applications.

LightWELD and portable laser welding are established solutions for welders and manufacturers worldwide, offering a user-friendly and efficient approach to modern welding processes.

The same LightWELD technology powers the LightWELD Cobot system. If needed, the portable LightWELD system can be disconnected from the cobot system for manual tool-less use.

Laser welding requires certain safety measures, like any other welding method. Laser welding is safe as long as operators and bystanders wear appropriate personal protective equipment (PPE) and the laser is used in a laser safety enclosure. Safety is a top priority for all LightWELD systems, which come with laser safety glasses and safe welding helmets for lasers. LightWELD laser units include features such as emergency stop buttons, safety interlocks, and easy integration with welding areas to stop the laser if the door is unexpectedly opened.

Yes, you can easily weld dissimilar metals such as copper to stainless steel or aluminum, as well as parts of different thicknesses across a variety of weld joint types.

You can use LightWELD at a 100% duty cycle at maximum laser power.

LightWELD offers seven operating modes to meet your needs:

• Wire welding: standard MIG wire is introduced into the laser weld to increase the size of the weld bead or compensate for poor part fit
• Fusion welding: the laser produces a continuous stream of light for maximum penetration and travel speed
• Pulse welding: the laser produces light pulses to reduce travel speed and heat input, creating a “stacked bead” appearance
• Spot welding: the laser delivers a controlled amount of energy to produce identical spot welds
• Dot welding: used to create multiple or overlapping spot welds
• Peak high power mode: short bursts of high power are used to weld reflective metals

Purchasing a LightWELD Cobot system is a simple process designed to meet your specific laser welding process and manufacturing needs. Just contact our team, and one of our automated laser welding specialists will assist you with product selection, integration guidance, and system deployment tailored to your welding applications.

Whether you’re working on automotive components, battery modules, or precision joints, we’ll help you define the right configuration, modular or custom, based on your processing needs. We also offer on-site validation, inspection support, and training to ensure a smooth transition into automated welding.

Our goal is to help you implement a cutting-edge laser welding solution that improves quality, increases productivity, and reduces costly rework.

Yes, modern laser welding systems are capable of performing high-precision welds on on very tight-fit joints (quasi zero-gap), when parts are properly prepared. This enables reliable hermetic sealing, which is essential for achieving hermetic sealing in applications like battery modules, medical components, and automotive enclosures. Thanks to the narrow laser beam and real-time monitoring systems, these systems deliver repeatable, high-integrity welds, even on challenging geometries.

Real-time monitoring ensures consistent weld quality by tracking variables such as laser beam alignment, seam quality, temperature, and material response during the weld. Integrated vision systems and sensors allow for dynamic adjustment of the laser welding process, reducing the risk of defects and improving overall production efficiency.

Absolutely. Automated welding solutions are designed for scalability and can handle high-volume production lines with minimal operator input. Their high-speed capabilities, combined with repeatability and low thermal distortion, make them ideal for industries such as automotive, electronics, and metal fabrication.

Yes, advanced laser welding heads and robotic systems can be programmed to follow intricate paths across complex geometries, adapting in real time to different metal components, thicknesses, and gap tolerances. This flexibility is enhanced by 3D vision systems, adaptive optics, and precise material handling modules.

By reducing labor dependency, minimizing rework, and enabling seamless integration with existing manufacturing systems, automated laser welding significantly lowers long-term operational costs. It also reduces the use of filler materials, shortens cycle times, and improves throughput, making it a cost-effective solution for both small and large-scale production environments.