Laser Welding 101: Everything You Need to Know About Handheld Laser Welders

Laser welding is changing the game in the metal fabrication industry. If you're a professional welder, a fabricator, or just curious about high-efficiency tools, this guide is for you. Progressive Welding Solutions created this comprehensive guide to break down what laser welding is, how it works, what it can and cannot do, and whether it’s the right fit for your workshop.

What Is Laser Welding?

Laser welding uses a high-intensity beam of light to melt and join metals. Unlike traditional methods like MIG or TIG, a handheld fiber laser welder delivers the beam through a cable to a pistol-like gun that the operator manually controls.

How Does It Work?

1. Laser Generation: A fiber laser source creates a focused beam of 1064nm infrared light.
2. Delivery: The beam travels through a fiber optic cable to the gun.
3. Welding: The laser melts the base metal, and optionally, a filler wire can be added.
4. Cooling: Most units are either water-cooled or air-cooled.

What Metals Can It Weld?

• Stainless Steel
• Mild Steel
• Aluminum
• Brass (with care)
• Copper (with high power)
• Titanium

What Thickness Can It Weld?

Power Level Max Single-Pass Thickness 1000W 0.5 – 3 mm 1500W 1 – 4 mm 2000W 1.5 – 6 mm

For materials thicker than this, edge preparation and multiple passes may be needed — but laser welding isn't ideal for thick structural jobs.

Can You Do Multi-Pass or Weave?

• Multi-Pass: Possible, but not ideal. Laser welding is designed for single-pass, precision welding.
• Weaving: Not recommended. Weaving can distort the beam focus and reduce weld quality.

Travel Speed and Settings

• Travel Speed: 10–60 inches per minute depending on material thickness and power.
• Wire Feed Speed (if used): 0.5–2.5 m/min
• Shielding Gas Flow: 10–15 L/min of Argon or Nitrogen
• Focus Distance: Typically 1–3 mm from the workpiece surface
• Angle: Torch angle should be between 10°–15° tilt for best penetration

Pros of Laser Welding

• High Speed – Up to 4x faster than TIG
• Low Heat Input – Minimal warping and distortion
• No Grinding Needed – Clean, aesthetic welds
• Low Consumables – Minimal spatter, no flux or stick electrodes
• Easy to Use – One-person operation
• Multi-Function Machines – Some models offer cleaning and cutting modes too

Cons of Laser Welding

• Expensive Equipment – Prices start around $6,000
• Not for Heavy Plate – Not suitable for structural welding above 6 mm
• Fit-Up Sensitive – Requires tight joint fit-ups
• Safety Risk – Class IV laser; requires goggles and barriers
• Power Quality Dependent – Sensitive to voltage fluctuations

Best Use Cases

• Stainless steel furniture
• Handrails and gates
• Sheet metal enclosures
• Automotive panels
• Kitchen equipment
• Signage and decorative work

What to Look For in a Machine

• Power: 1500W is versatile for up to 4 mm steel/aluminum
• Cooling: Water-cooled for long sessions; air-cooled for portability
• Wire Feeder: Optional but good for large gaps and corner welds
• Dual Gas Control: Better protection and weld consistency
• Warranty and Support: Choose trusted brands with replacement parts available

Recommended Machines

1. OMTech 1500W Handheld Fiber Laser Welder

• Great for shops doing daily stainless/aluminum work
• Compact and water-cooled
• View Product

2. Cloudray 1500W Air-Cooled 3-in-1

• Includes welding, cleaning, and cutting
• Portable, less maintenance
• View Product

3. MCWlaser 1500W Air-Cooled

• Air-cooled with dual-mode control
• Works on 110V, ideal for workshops with limited power supply
• View Product

4. Miller OptX 2kW Industrial Welder

• For heavy-duty industrial applications
• Top-tier quality and support
• View Product

Safety Tips

• Wear laser-rated safety goggles (OD 6+ for 1064nm)
• Enclose the area or use laser barriers
• Wear full PPE including gloves and non-reflective clothing
• Keep a CO₂ fire extinguisher nearby

Final Thoughts

Laser welding opens a world of speed, quality, and aesthetic excellence — especially for fabricators and solo welders working with stainless, aluminum, or thin metals. With the right training and machine, it can multiply your shop's efficiency while reducing post-weld cleanup.

At Progressive Welding Solutions, we’re exploring laser welding as the next evolution in our fabrication process. Stay tuned as we bring this technology to our operations and share hands-on results.