Handheld Laser Welding is the latest technological advancement in welding and fabrication. Utilising a fibre optic laser beam, metals can be welded together quickly, efficiently and has changed the game for welding applications across the industry. This handheld laser welding option is a more manual process (or can be paired with Cobots and Robots) to bring down the cost compared to fully automated laser welding systems.
LightWELD™ handheld laser welding and cleaning systems are fast, easy to learn and operate, and produce high quality, consistent results across a wide range of materials and thickness’s. Pre-weld and post-weld laser cleaning functionality optimises weld quality while increasing productivity.
LightWELD™ enables dramatically faster welding and is easier to learn and operate than MIG or TIG. LightWELD™ provides higher-quality, consistent results with minimal distortion or part deformation.
IPG LightWELD 1000
Welding Capability
Steel – up to 4mm
Aluminium 3 & 5 Series – up to 4mm
Aluminium 6 Series – N/A
Titanium & Nickel Alloy – N/A
Copper – N/A
Cleaning – N/A
IPG LightWELD XC
Welding Capability
Steel – up to 4mm
Aluminium 3 & 5 Series – up to 4mm
Aluminium 6 Series – N/A
Titanium & Nickel Alloy – N/A
Copper – N/A
Cleaning – Pre-Weld & Post-Weld
IPG LightWELD XR
Welding Capability
Steel – up to 6.35mm
Aluminium 3 & 5 Series – up to 6.35mm
Aluminium 6 Series – up to 3mm
Titanium & Nickel Alloy – up to 5mm
Copper – up to 2mm
Cleaning – Pre-Weld & Post-Weld
IPG LightWELD XR 2000
Welding Capability
Steel – up to 8.25mm
Aluminium 3 & 5 Series – up to 8.25mm
Aluminium 6 Series – up to 5mm
Titanium & Nickel Alloy – up to 7mm
Copper – up to 3mm
Cleaning – Pre-Weld & Post-Weld
Interested in a demonstration?
We’re excited to announce the launch of our very own Laser Welding demonstration vehicle, as well as a demonstration booth in our Herefordshire showroom. If you’d like to request a demonstration, either come and visit us, or we can come to you!
Handheld Laser Welding vs Conventional Welding Techniques
LightWELD™ enables dramatically faster welding and is easier to learn and operate than MIG or TIG. LightWELD™ provides higher-quality, consistent results with minimal distortion or part deformation.
TIG welding can generate extreme heat that deforms thin materials and produces poor visual finishes. Welding copper is difficult and welding metals of dissimilar thickness’s is limited. TIG welding is a highly skilled process, and experienced TIG welders are a scarce resource.
MIG welding requires consumable wire, material pre-cleaning, and bevelled joints for full penetration of thick metals. Travel and working angles are limited, and vertical positions can be extremely challenging. MIG is a high-heat process that can cause part deformation.
LightWELD™ systems are easier to learn and operate and are 4X faster than TIG welding. The low heat input and extensive material and thickness capabilities increase productivity, repeatability, and improve weld quality for operators of all skill levels.
Features & Operation
Handheld Laser Welding power up to 2000 W is easily adjusted with intuitive controls to quickly dial in optimum weld settings for various materials and thickness’s. With up to 74 stored pre-set and user-defined process parameters, novice welders can be trained and welding in a matter of hours.
Optional Wire Feeding Package
- Wire welding capability extends laser welding applications to poorly fit-up parts.
- Used for low carbon steel, stainless steel, aluminium, non-ferrous metals & alloys.
- Either a single or dual wire feeder set-up can be utilised for extra strength and filling larger gaps.
The hand-held welding & cleaning gun is compact, ergonomic, and comfortable. Specially designed nozzle tips for welding and cleaning applications, plus built in wobble functionality enable operators to produce high quality welds consistently. Nozzle tips switch out quickly and easily to accommodate fusion welding, wire welding, and cleaning, further optimizing and increasing productivity.
- Built-in parameters ensure high-quality results and can be customised for later use.
- Operators can instantly switch between pre-sets to accommodate many material thickness combinations.
- Simple controls allow new welders to be trained within hours and experienced welders realise an immediate increase in productivity.
- Create highly aesthetic seams and weld parts with poor fit up.
- Adjustable frequency and weld width up to 5 mm optimises results.
- Wobble parameters are pre-programmed and can be adjusted on the fly, saved, and recalled immediately.
Simple Installation and Operation
Clearly labelled rear connections make getting started fast and easy. Just plug in the power cord and gas connection, attach the work piece clamp, and the system is ready to go. Laser power, gas and gun control is delivered through a single cable.
An Ethernet computer connection provides access to advanced settings to fine tune and save process parameters.
Nozzles and Consumables
LightWELD™ systems are extremely economical in the consumables parts that they use.
Each system is supplied with 4 different welding nozzles, and 3 different cleaning nozzles.
The nozzles are quick and easy to swap and exchange, with a quick release collet, allowing for rapid changing between welding and cleaning.
The assorted nozzles are perfectly suited for various types of welding or cleaning, for optimum performance.
Welding Nozzles
The 4 welding nozzles consist of are supplied to suit a variety of applications:
- 1-Point (General Purpose)
- 2-Point (6mm)
- 2-Point (9mm)
- Circle
Cleaning Nozzles
The 3 cleaning Nozzles allow you to work with a variety of angles and positions, such as flat, or outside corners.
- 2-Prong Nozzle
- Outer Cleaning Nozzle
- 1-Prong Cleaning Nozzle
Note the LightWELD 1000 does not have a cleaning function or these nozzles.
Extension Bars
The system is also supplied with a dual-extension tube, one of 58mm and another of 10mm, to suit various applications as required.
This is to allow for different laser beam focusing lengths on varying materials
and applications.
“In my 41 years in the business, I have never seen a welder that allows beginners to make welds like seasoned pros!”
Laser Welding Safety
When it comes to Handheld Laser Welding, safety is of the up-most importance.
Given that laser welders utilise Class 4 laser diodes, all welding should be completed in a laser-proof workspace.
Morgan Rushworth Laser Safe Enclosures can be built to suit any space due to their modular design.
Simply measure your intended space, and you can build your enclosure to suit from assorted panels, including safety interlocked doors, solid panels, or windowed panels featuring laser safety glass to allow light into the enclosures for operator comfort.
Laser Safety Glass
In the case of a reflected beam, the Laser Safety glass will absorb it keeping people outside of the booth safe.
Roof Panels
A roof is required if there is any space overlooking the booth, such as a second floor, or a mezzanine.
Lighting System
Typically used with the roof panels, although installable without, additional lighting makes working in the laser safe enclosure easier and more convenient.
Safety Interlock
To prevent unintended access, the door is fitted with a safety interlock, stopping the welder the moment the door opens. Protecting anyone who happens to open the door unexpectedly.
PPE and Extraction / Filtration
As well as the protective space, PPE is vital to protect the health and well being of operators.
Laser-Safe Glasses & Helmets
To this extent specialist welding helmets are required that also feature Laser protection as well as laser-safe glasses. Laser’s operate on a specific electromagnetic wavelength, and would cause permanent retina damage if they were to reflect back into your eyes. As such, a standard welding helmet is not sufficient protection.
Specially made glass is required for both helmets and protective glasses to ensure total safety when using a Class 4 laser such as a Laser Welder.
Extraction / Filtration
It is also vital to have adequate extraction and filtration in place to remove any fumes generated from the welding processes as well. Whether this is localised filtration, or linked to a larger LEV system.
Our Morgan Rushworth MME Mobile Welding Extraction provides a simple, portable solution for extracting the harmful fumes from welding. Compared to traditional MIG & TIG operations, Laser Welding produces much less emissions, but for full safety they should still be paired with an extraction unit.
As well as the standard IPG Laser Welding Helmets, we also offer the Optrel Panoramaxx Hybrid CLT.
This advanced welding mask offers full laser-safe protection, with a near translucent window for enhanced visibility.
It can be paired with the SwissAir Respiratory Protection System for a complete PPE solution.
Would you like a demonstration?
If you’d like a demonstration of the system, either at your premises, or ours, please complete the form below.