Laser Welding

Laser welding joins metals with a focused laser beam to create narrow, deep-penetration welds with low heat input and minimal distortion at high speed.

Overview

Laser welding (laser beam welding) uses a concentrated laser to melt and fuse metals along a joint line, typically through fiber or disk laser systems with shielding gas and precise fixturing. It excels at narrow welds, high travel speeds, deep penetration, and low overall heat input—useful when distortion control and cosmetic seams matter.

Choose laser welding for thin to medium sections, tight assemblies, and repeatable production where the joint can be accurately located and clamped. It handles stainless, carbon steels, nickel alloys, and many aluminum applications, including dissimilar metal joints in some cases.

Tradeoffs: fit-up and joint cleanliness are critical; gaps quickly drive defects or require filler strategy. Capital cost is higher than arc welding, and reflective materials (aluminum, copper) need the right wavelength/power and process window. Access to the joint line and stable fixturing strongly influence quality and cost.

Common Materials

  • Stainless steel 304
  • Stainless steel 316L
  • Mild steel (1018)
  • Aluminum 6061
  • Inconel 718
  • Titanium Grade 2

Tolerances

±0.005"

Applications

  • EV battery tab and busbar welds
  • Medical device housings and seams
  • Hermetic sensor and actuator packages
  • Automotive transmission components
  • Stainless tubing and manifolds
  • Aerospace thin-wall brackets and assemblies

When to Choose Laser Welding

Laser welding fits parts that need low distortion, narrow heat-affected zones, and repeatable weld placement in production. It works best when you can control joint fit-up, surface condition, and clamping, and when cycle time and cosmetic seams are important. It’s commonly justified for medium to high volumes or high-value assemblies where rework risk is costly.

vs MIG (GMAW)

Choose laser welding when you need lower heat input, less distortion, and a narrower bead than MIG can reliably deliver. It’s a better fit for thin sections, tight assemblies, and high-speed automated seams where spatter and post-cleanup are unacceptable.

vs TIG (GTAW)

Choose laser welding when TIG’s travel speed and heat input create distortion, wide HAZ, or excessive operator-time cost. Laser welding gives more repeatable results in production, especially on long seams or high-count weld patterns that benefit from automation.

vs Stick (SMAW)

Choose laser welding for precision assemblies, thin materials, and controlled manufacturing environments where weld appearance, repeatability, and minimal cleanup matter. Stick is better suited to field work and heavy sections; laser welding is better for tight, fixtureable joints.

vs Resistance Welding

Choose laser welding when the joint isn’t a lap joint between accessible electrodes, or when you need a continuous hermetic seam instead of discrete nuggets. Laser welding also helps when part geometry limits electrode access or causes electrode wear/marking issues.

vs Electron Beam Welding

Choose laser welding when you want deep penetration without the lead time, size limits, and cost of vacuum chamber processing. Laser welding supports high throughput and easier integration into production cells while still providing a narrow weld and low distortion.

Design Considerations

  • Design joints to be self-locating (step, scarf, or tongue features) to control seam position and reduce fixturing complexity
  • Hold tight fit-up; keep gaps minimal and consistent because laser welding is sensitive to joint mismatch and opening
  • Specify joint type, weld length, and acceptance criteria (porosity, undercut, cosmetic class) so shops can quote the right process window and inspection
  • Provide line-of-sight access for the laser head and shielding gas nozzle; avoid hidden seams that force complex optics or multi-axis setups
  • Call out surface prep requirements for plated, painted, or oily parts; contaminants and coatings can cause porosity and lack of fusion
  • Plan for distortion control with symmetric weld patterns and robust clamping; thin parts may still move even with low heat input