Common Misunderstandings About Laser Welding
July 17, 2025Laser welding is a relatively new but widely adopted method for joining metals and plastics. Its precision, speed, and high quality suit many state-of-the-art applications today.
Although laser welding has been around for years and offers various advantages, many older welders remain skeptical about it. Common misconceptions concern complexity, expenses, and safety.
In this article, we will address common laser welding myths and misunderstandings that often discourage potential users. Understanding the fundamentals of this process is crucial in making the right choice for your business, so let's learn more.
Laser Welding Process
Source: https://www.youtube.com/watch?v=3wHae9FcIHU
Brief Overview of Laser Welding
Laser welding, also known as laser beam welding (LBW), is a metal joining process that utilizes the heat of a laser to melt and fuse the pieces. Besides metals, lasers can also join acrylic, PVC, PC plastics, or composites.
The use of lasers in the industry is almost as old as the discovery of lasers. The first type, the CO2 laser, provided raw horsepower, relatively inexpensive operating costs, and ease of maintenance.
The working principle of laser welders is quite simple. The source generates the laser beam, which is transferred through an optical fiber. However, the raw power of the laser beam is not high enough to melt, fuse, or cut through pieces.
That's why systems use curved mirrors or a curved surface lens to focus the light down to a spot size. Focusing the raw light into tiny spot sizes creates extremely high power density. Depending on the power density, lasers can either melt or completely evaporate the surfaces.
Laser Welding Principle
Source: https://www.stylecnc.com/
Common Laser Welding Myths and Misconceptions
Like any technology, lasers have undergone significant advancements since their introduction in the 1960s.
Some misconceptions have persisted since the introduction, while others have emerged due to advancements in the field. To avoid making mistakes and make an informed choice, we will go through the most common laser welding misunderstandings.
Source: https://www.youtube.com/watch?v=fhijeYDXHkg
Here is a brief overview table of 10 common myths and truths about laser welding
| Myth | Truth |
| Laser welding is too expensive | Initial investment is high, but the ROI is very fast |
| Lasers are best suited for high-tech industries and large businesses | There are new, compact systems that are cheaper and better suited for smaller shops and everyday applications |
| Laser beam welding is complex and requires extensive training | While equipment is more complex compared to arc welding, the fundamentals are similar, and training courses can be super-short |
| Laser welding works best with thin sheet pieces | Lasers can work with anything from sheet metal to thick, heavy industry parts |
| The more power a laser has, the better | High-powered laser systems are expensive, and they can consume unnecessary power if not needed |
| Laser systems don’t need monitoring or maintenance | Monitoring systems keep track of laser efficiency and results, allowing operators to optimize the process and schedule the necessary maintenance |
| Lasers can work without preparation, focus, or alignment | Laser welding requires squeaky-clean edges, and proper focus and alignment for precision |
| Laser welding is safer than arc welding | Each type of welding has unique hazards |
| You can use the same parameters for any metal | Laser is less efficient on reflective metals with high thermal conductivity |
| Automated laser welding systems can work independently | Automated systems require skilled and trained operators to ensure optimal performance |
Let's further explain and debunk the myths surrounding laser welding.
Myth 1: Laser welding systems are too expensive
Yes, laser welding systems are more complex than ordinary arc welding setups, which is why they have a higher cost. However, you'll need to consider the broader perspective.
Laser beam welding offers numerous advantages, such as high welding speed, efficiency, accuracy, and quality. Systems are easily automated, reducing the risk of operator error and producing high-quality, clean welds.
Clean, high-quality welds result in less time spent on post-weld cleaning and reworking. The reduced need for rework, combined with faster processing times and the ability to weld a broader range of materials, can all contribute to a positive return on investment.
Clean, High-Quality Laser Welds
Source: https://www.lasertherm.cz/
While initial investment in high-end laser welding systems can surpass six figures, long-term benefits often outweigh the costs. Keep in mind that there are also more affordable and compact laser welding solutions that can benefit smaller fabrication shops.
The key is to understand the ROI. Laser welding systems have an average return on investment (ROI) of 18 to 24 months, resulting from savings in labor, reduced scrap, and increased productivity. It's up to you to calculate if that's applicable to your applications and rate of work.
Myth 2: Laser welding is only for high-tech industries and large shops
It is true that laser welding originated in high-tech industries such as electronics, aerospace, medical device manufacturing, and defense system manufacturing. However, that's due to the fact that lasers were a breakthrough technology that was expensive and scarce.
Today, laser welding systems are more accessible and less expensive. As a result, manufacturers use it in general metal fabrication, the automotive industry, or jewelry making. Additionally, laser welding systems have become more compact. Low-power, compact laser solutions are inexpensive and also suitable for small fabs or jewelry shops.
You don't need a large-scale manufacturing business to justify investing in a laser. Small shops can also benefit from the speed, efficiency, and accuracy of laser beam welding.
Source: https://www.youtube.com/watch?v=fhijeYDXHkg
Myth 3: Laser welding is complex and requires extensive training
Laser welding systems are more complex than arc welders. They include a series of delicate components, such as fiber optics, lenses, and mirrors. However, in a nutshell, these systems utilize the same parameters as arc welders, including power, voltage, pulse, shielding gas flow, and so on.
Therefore, welders who know how to work with a torch and understand the fundamental properties of metals can easily adapt to laser welding systems. Due to the increased popularity of lasers, numerous courses are now available. Some are just three days long, covering the fundamentals of laser welding, including theory, equipment, safety, and practical applications.
Today, there are also handheld lasers that are super-easy to use and learn. They are not too different from regular arc welding systems, so mastering them is even easier. Learning new skills and staying ahead is crucial to maintaining a competitive edge in today's welding industry.
Handheld Laser Welding Process
Source: https://www.bodor.com/
Myth 4: Laser welding is only suited for thin, sheet pieces
The extensive use of laser welding in applications that involve sheet metal welding, such as automotive body panels, electronics, or battery manufacturing, has led many to believe that lasers are only suitable for thin sheet welding. Additionally, the first lasers had fairly limited power.
Lasers can indeed make exceptional welds on thin sheets. Their precision and narrow heat-affected zone can yield nearly invisible welds without thermal distortion or warping on sheets. However, new lasers are surely more capable than that.
Fiber Laser Welding Thin Sheets
Source: https://nissho-astec.com/
For example, fiber lasers can output more than 50 kW of energy. Other heavy hitters include CO2 lasers that output up to 20 kW and Nd: YAG lasers with outputs of up to 10 kW. This energy, combined with focal length and travel speed, can enable laser welders to join significantly thick parts.
Focusing high power down to a tiny spot produces extreme power density. This power melts, evaporates, and penetrates the metal, forming a cavity known as the keyhole. Manufacturers use high-power laser welding to join thick parts, such as car frames, plane panels, large ship hulls, and steel components for bulldozers and excavators.
Laser Welding Car Frames
Source: https://www.laserfocusworld.com/
Myth 5: The more power, the better
The more power the laser has, the deeper it can penetrate the base pieces. However, in real-life applications, the more the better can be an ineffective and expensive approach.
First of all, lasers are power-hungry, and not all of them are super efficient. The more power it has, the more power it will consume to operate and work. If less efficient, most of that power is going to waste, while only a fraction is converted into welding power; so, keep that in mind.
Before purchasing a laser system, adjust the power to suit your specific needs. That includes evaluating the thickness and type of metals you typically weld. Buying the highest-power laser can be highly cost-inefficient, as these systems are initially more expensive.
If you have the right laser for your applications but feel it underperforms, increasing the power is not always the right solution. First, reevaluate the parameters and preparation for the given metal. If everything appears to be fine, check for aged, damaged, or contaminated optics. Increasing the power is not always the best solution for underperforming lasers.
Check and Clean Optics Periodically for Laser Welding
Source: https://ca.omtechlaser.com/
Myth 6: Laser systems don't need monitoring or frequent maintenance
State-of-the-art laser welding systems are so advanced that they can produce enormous amounts of repetitive welds with minimal operator interference. That led many manufacturers to believe that machines don't require monitoring or frequent maintenance.
In reality, laser systems contain components that degrade or fail over time due to periodic use. While newer systems have debris management protection, degradation is inevitable, so frequent monitoring and maintenance are mandatory.
The latest laser systems use laser power meters and beam profiling to monitor laser performance. Although these additions increase the overall price, they provide trend analysis, process traceability, and smarter maintenance prediction. Monitoring the condition and results of the laser and its components provides the operator with valuable insight. Valuable data can increase process efficiency and reduce downtime by enabling more effective maintenance scheduling.
Laser Power Meter for Controlling and Monitoring Laser Performance
Source: https://www.laser-beam-profile.com/
The frequency and price of maintenance are highly dependent on the type of laser and laser welding equipment. For example, CO2 lasers operate at a forgiving 10.6-µm wavelength, and optics are robust and debris-resistant. As a result, they are more durable and cheaper to maintain.
Meanwhile, newer types of lasers, such as fiber or diode lasers, operate at nearly a 1-µm wavelength. They use delicate optics that are susceptible to damage by debris. As a result, most newer lasers are not designed for harsh industrial environments.
Fiber Laser Welding a Stainless Steel Railing
Source: sfcnclaser.com
Myth 7: Lasers can work without preparation, calibration, focus, or alignment
Lasers can yield outstanding welds known for their precision, cleanliness, and quality. Some welders think you can get perfect results even if you disregard the preparation, calibration, focus, or alignment. In reality, any welding method, especially laser welding, is highly dependent on proper weld preparation.
Surface Cleaning Before Laser Welding
Source: https://www.lightweld.com/the-weld-shop/laser-weld-preparation-cleaning/
The first step in producing high-quality, repetitive laser welds is calibration. Frequent parameter calibration ensures your welding system is up for the task, and you can trust your settings. A quick calibration can spare you from wasted materials and botched parts.
Weld preparation includes thoroughly cleaning surfaces before welding. In laser welding, even the smallest amounts of grease, dirt, or contamination can significantly impact the laser power, resulting in unpredictable outcomes. Regarding cleanliness, laser welding is even more demanding than TIG welding.
Laser beam welding is highly accurate, but precision is achieved through proper laser focus and alignment. The laser gains power as the light is focused into a tiny spot, which carries a high energy density. Failing to focus or align the power can significantly reduce the efficiency and precision.
Focusing the Laser Beam to Achieve High Energy Density on the Part
Source: https://www.cailabs.com/blog/industrial-laser-processing/laser-welding-what-solutions-can-respond-to-industrial-challenges/
Myth 8: Laser welding is safer than arc welding
Each welding method and type poses a specific risk. When automated, laser welding is typically safer than arc welding, as welding arms and robots limit operator exposure to hazards.
New laser welding systems also comprise shields, interlocks, and ventilation, but you shouldn’t disregard the safety. Lasers may not deliver visible light or sound, making accidental exposure harder to detect.
Laser Welding Systems with Ahields, Interlocks, and Ventilation
Source: https://selmach.com/
Lasers in welding systems produce highly concentrated, intense light that fundamentally melts and fuses the pieces. However, if reflected, a laser beam can cause severe eye damage or burns. Direct or reflected beams can cause deep skin burns or permanent retinal damage.
Some welders believe lasers produce less fume than arc welding. In reality, laser welding can produce ultrafine metal and chemical particulates. Sometimes, these particles can be more toxic than arc welding fumes due to higher temperatures and precision vaporization.
Laser Welding Produces Ultrafine Particles—Invisible but More Toxic
Source: https://safe-welding.com/
Meanwhile, arc welding carries a greater risk of electric shock, visible UV burns, and noise-related injuries. Fundamentally, welders work very close to an arc that emits radiation, heat, and fumes as it melts the pieces. Therefore, we cannot say that one process is safer than the other, although advancements have improved worker safety.
Before purchasing or using the laser welding system, ensure that the machine complies with local or international safety standards. During the procedure, don't skimp on PPE. Laser-rated goggles and a ventilated workspace are non-negotiable. All welding courses today, including laser welding, comprise welding safety protocols and practices, and it is crucial to follow them during your work.
Wearing PPE During Laser Welding
Source: https://www.thefabricator.com/
Myth 9: You can use the same parameters for any material
The versatility of laser welding enables it to join a wide range of materials, including metals, acrylic, PVC, PC plastics, and composites. However, you should be aware that different materials interact differently with the laser, meaning you cannot use the one-size-fits-all approach.
Laser Welding of Automotive Plastic Taillight Components
Source: https://www.youtube.com/watch?v=Gxhk4WEtY08
One of the biggest drawbacks of lasers is that they have limitations due to the properties of the metals they interact with. Thermal conductivity and reflectivity can reduce the efficiency of a laser, causing it to bounce off the surface rather than dig into it.
Mild steel is the most laser-friendly metal to weld. It lacks a reflective surface or high thermal conductivity, allowing the laser to penetrate deeply even with limited power. Meanwhile, aluminum, copper, or brass have shiny surfaces and high thermal conductivity. As a result, lasers need much more power to fuse or cut those pieces compared to mild steel.km,,,,,,jbvg c
Laser Welding Copper to Aluminum
Source: https://www.youtube.com/watch?v=DPi1DC_Mr0E
For example, a 500W laser can cut up to 6mm (approximately 1/4") thick carbon steel. Due to reflectivity, it can only cut up to 2mm (approximately 1/16") thick copper, aluminum, or brass. Similar rules also apply to welding. Depending on the application, an 8 kW laser can weld up to 15 mm (approximately 5/8") of steel but down to 12 mm (almost 1/2 inch) of stainless steel.
As a result, you will have to tune the parameters based on the metal you are welding or cutting. You cannot weld the same thickness of mild steel and aluminum with the same set of parameters, and that's something you probably learned with arc welding.
Laser Welding Carbon Steel Process
Source: https://dplaser.com/
Myth 10: Automated laser welding systems don't need manual labor
Due to the welder shortage, many manufacturers are switching to welding automation, including automated laser welding systems. These systems feature robotic arms, fixturing systems, and positioners that independently move and weld the pieces with minimal human intervention.
Machines doing all the hard work made many welders think they would completely replace them. But, in practice, automated systems cannot work without skilled and trained operators.
Machines are just expensive toys without a skilled operator. Operators must understand the machine's settings and programming to ensure optimal performance. Machines communicate back through monitoring and feedback systems, but it's up to operators to figure out how to make the process more efficient and safer.
Automated Laser Welding Process
Source: https://www.metalformingmagazine.com/
Final Thoughts
Laser welding remains a relatively new and expensive technology for many businesses. The introduction of a new technology often gave rise to many misunderstandings and misconceptions.
However, technology is continually evolving and changing as scientists and inventors address various issues. That's why modern laser welding is much less expensive and more user-friendly, even for smaller businesses.
Debunking the myths about laser welding can help you understand the true power and limitations of this process. The ultimate goal is to develop a system that enhances your efficiency, speed, and weld quality while also mitigating the constraints and drawbacks of laser welding.
🧐 Common Misunderstandings About Laser Welding FAQ