Portable, reliable, and versatile – these are some of the upsides of a handheld laser welder versus traditional welding equipment. And as manufacturers discovered its impressive precision and efficiency, the industrial applications of these machines have become widespread.
In this article, we present the most common handheld laser welding machine applications such as in the transportation, electronics, and general metal fabrication sectors.
Why Manufacturers Are Switching to Handheld Laser Welding?
It is no secret that handheld laser welding machines come at a high upfront cost, yet many manufacturers have switched to this solution. The benefits of these machines outweigh the high initial capital they require.
Speed & Efficiency
Most handheld laser welders operate with extreme precision and support automation features. Hence, these machines can weld about five to ten times faster than the traditional methods (e.g., TIG and MIG welding).
Laser welding’s high speed ensures minimal formation of heat-affected zones (HAZ), which guarantees a clean weld. This results in minimal post-processing, which significantly cuts down production time.
Precision & Aesthetics
In laser welding, a concentrated thermal beam (~0.1 to 1 mm in diameter) penetrates and melts the workpieces while containing the spread of heat. This provides the operator with precise control during the welding procedure, which ensures minimal metallurgical distortion.
Furthermore, handheld laser welders have rapid heating and cooling rates that help in the preservation of the base materials. This contributes to the production of an aesthetically pleasing and durable joint that is ideal in the electronics and metal fabrication industries.
For instance, Denaliweld’s Air‑Cooled Laser Welding Machine (90 lb), which delivers 1 to 3 kW laser power, features a seam tracking system for precise beam application even in intricate material geometries. This machine also features an advanced laser control system that allows you to produce your desired output curve, as well as a built-in chiller system to ensure it operates at a safe temperature level.
Flexibility & Portability
Handheld laser welders feature a lightweight and compact profile for great flexibility and portability. This enables the operator to work in tight or unconventional spaces or transport between job sites easily. For this reason, most handheld laser welding machines can function even without a fixed working station.
Lower Operating Costs
Laser welding drives down operating costs in multiple ways. First, it reduces the use of filler materials and consumables because the focused beam alone can effectively melt the base materials. Second, rework and material waste is minimized as laser welding produces clean and robust welds with its ultra-precision and rapid cooling rates. Third, handheld laser welders are easy to learn, so it only require minimal training to prepare an operator for a laser welding project.
Key Applications of Handheld Laser Welding Machines
The demand for more durable and higher-quality industrial products has increased steadily in recent years. And manufacturers found that the precision and efficiency of handheld laser welders were the best solution to meet this increasing demand.
Here are some of the astounding industrial applications of this technology.
Automotive & EV Manufacturing
The mobility of handheld laser welders enables the operator to weld directly on large vehicle frames or in restricted spots. Hence, this equipment is ideal for spot welding vehicle body panels, battery housings and components, and assembling prototypes. Furthermore, the machine’s focused laser beam guarantees low thermal distortion, which promotes robust vehicle joints that can resist stress and pressure.
Aerospace & Aviation
Most aircraft (and even spacecrafts) have welded aluminum or titanium components. Compared to traditional methods, handheld laser welders can deliver the optimal precision and power to maintain the integrity of base aluminum or titanium materials used in the aircraft. This results in high-strength aircraft alloys with minimal warping and contamination that comply to safety and quality standards.
Metal Fabrication & Construction
When it comes to on-site repairs and custom metal fabrication, handheld laser welders provide impressive versatility. They enable quick and clean repairs on railings, steel frames, and gates without the logistical challenge of moving large items to a work site.
Electronics & Appliances
Handheld laser welders excel at micro-welding delicate parts such as smartphone frames and electrical connectors. They are also highly effective for joining stainless steel enclosures used in some home appliances, like ovens and refrigerators.
Consider Denaliweld’s JET EZ micro fiber laser welding machine model, an ultra-light and portable 22-kilogram laser welder made for on-site and remote applications. As with most Denaliweld models, the JET EZ model features an advanced laser control system that enables easy and swift fine-tuning of laser parameters for appropriate application to thin or delicate materials, such as electronic components.
Medical Devices & Home Use
The medical device industry demands sterile and accurate welds for surgical tools and implants. This is only possible if the joints are durable, smooth, and free of material contamination. Handheld laser welders can produce medical-grade joints that adhere to strict hygiene standards.
For home installations, handheld laser welders can deliver cosmetic and clean welds on materials like stainless steel, which are widely used in visible fixtures in kitchens and bathrooms.
Practical Considerations When Using a Handheld Laser Welder
For a safe and effective application of handheld laser welders, the following considerations must be observed.
- Material Compatibility: The machine’s parameters must be configured to suit the composition and properties of the workpieces. For instance, thin stainless steel often requires 800 to 1200W of laser power, while the thick ones require up to 2000W.
- Shielding Gas Requirements: This gas protects the weld pool from atmospheric contaminants that can degrade the weld quality. Make sure to use the right shielding gas for the materials involved in the welding process. For instance, around 15L/min application of Argon or Nitrogen gas is needed as a shielding gas for stainless steel workpieces.
- Workspace Setup: To avoid respiratory issues, the workspace must be well-ventilated. The area must be free from reflective surfaces to prevent accidental laser reflections that can damage the operator’s eyes or skin. And for safe maneuvering of the equipment, an adequate space must be provided.
- PPE and Safety: The operator must wear appropriate personal protective equipment, including laser safety glasses rated for the specific laser wavelength and protective gloves, to shield against heat and sparks. Flame-resistant clothing is also recommended to minimize the risk of burns.
Supercharge Your Production Quality and Efficiency With A Handheld Laser Welding Machine
The emergence of handheld laser welding machines is a significant step up in the welding industry. Its high-level precision, optimal heat input, fast welding speed, and impressive flexibility make it the ideal choice for most industrial applications, such as in the electronics, automotive, aerospace, and medical device production sectors.
For top-quality handheld laser welding solutions, visit Denaliweld. We are a premier global brand of modern laser welding technologies. Reputable laser professionals and engineers develop our machines, so their structure, ergonomics, and features are suitable for modern industrial applications. With our machine’s advanced laser control software and user-friendly design, you can easily utilize it to supercharge your firm’s production.
