Handheld Laser Welding and Cleaning Systems

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Overview

Overview Capabilities Specifications Support FAQ

LightWELD Unbeatable Benefits

FAST: Up to 4X faster than TIG
VERSATILE: Wide range of materials – up to 1/4 in. (6.35 mm)
EASY: Optimized presets reduce learning curve
CONSISTENT: High-quality, repeatable results
FLEXIBLE: Simple and challenging applications
PRODUCTIVE: Pre- and post-weld cleaning capability

Learn More - Download LightWELD Brochure

LightWELD Handheld Laser Welding and Cleaning Systems can be used as a laser welder and handheld laser cleaner

LightWELD - Turnkey Handheld Laser Welding & Cleaning Systems

Adjustable laser welding power up to 1500 W
Preset & user-defined modes optimize material-thickness combinations
Wobble welding controls for 5 mm of additional weld width
Rear panel provides intuitive connections for power, process gas and external accessory controls
Cleaning power up to 2500 W peak for greater welding quality and finishing capability

	Traditional Welding Methods	LightWELD Laser Welding & Cleaning
Speed	Average	Up to 4X Faster than TIG
Quality	Depends on user experience	Consistent high-quality results
Learning Curve	Steep	Quick and easy
Material Flexibility	Limited with consumables changes	Wide range with no set up
Distortion & Deformation	High	Very Low
Heat Affected Zone	Large	Small
Wobble Welding	No	Yes - up to 5 mm additional weld width
Pre- and Post Weld Cleaning	No	Yes - up to 15 mm cleaning path

TIG welding is a time-consuming, two-handed welding method that requires an experienced, highly-skilled operator. TIG welding may generate extreme heat that deforms thin materials, produces poor visual finishes, is difficult when welding copper, and limited when welding metals of dissimilar thicknesses.

MIG welding requires consumable wire, material pre-cleaning and beveled joints for thick metals for full penetration. Travel and work angles are limited and vertical positions are extremely challenging.

LightWELD enables dramatically faster welding, is easier to learn and operate, and provides higher-quality, consistent results across a wider range of materials and thicknesses than MIG or TIG with minimal distortion, deformation, undercut or burn-through.

The low heat input and extensive material and thickness capabilities increase productivity, repeatability, and improve weld quality for operators of all skill levels. LightWELD welds dissimilar metals of different thicknesses with ease and creates aesthetic high-strength joints with minimal or no consumable wire. Plus, LightWELD XC and LightWELD XR offer built-in pre- and post-weld cleaning not found on any traditional system.

LightWELD - Factory Presets Ensure Optimized Welds & Cleaning

Simple preset selection ensures consistent high-quality laser welds and cleaning
Presets include wobble welding function to accommodate wider seams and for parts with poor fit-up
Operators can instantly switch between presets to process multiple material-thickness combinations
Advanced operators can customize presets, save for future use and can be used by novice operators to produce the same results
Novice operators require less training which reduces labor costs while preserving quality, increasing productivity and decreasing scrap

LightWELD is Fast & Easy to Set Up

Ergonomic, compact and proven to be the most comfortable and easy to use laser gun with built-in wobble welding functionality.
2-step trigger and part contact sensor enhance operator safety
Purpose-built nozzle tips for various weld joint types and pre and post weld cleaning applications
Quickly switch from standard laser welding to wire welding, and from laser welding to laser cleaning
A single cable from the unit delivers laser power, gas and control connections to the gun

Fast and Easy Setup

Clearly labeled rear connections make getting started fast and easy
Simply plug in power cord and gas connection, attach clamp to work surface, and the system is ready to go.
Laser power, gas, and gun control are delivered through a single cable.
An ethernet computer connection provides access to advanced parameter settings to fine tune and save process parameters.

LightWELD Operator Safety Features

Key switch control to secure system from unauthorized operation
Emergency-stop button for immediate shut down
Safety interlock verifies integrity of laser delivery to the welding gun
2-step weld gun trigger, enable and then fire, for intentional operation
Part contact electrical interlock turns off the laser power if the welding head is not in contact with the welded parts
Door switch interlock circuits shut down laser if anyone other than operator unexpectedly enters the welding area

LightWELD is a Class IV laser system and safety precautions are required. Operator protective equipment including welding gloves, welding shield and 1070 nm laser-safe glasses are required.

LightWELD Material & Thickness Welding Range

Thick, thin, reflective and dissimilar metal welding without wire that
is difficult or impossible with traditional methods, plus weld materials with different electrical conductivity

laser weld steel, aluminum, and copper

High-speed welding across a wide range of materials and thicknesses
Low heat input for minimal part distortion or deformation
Built-in factory presets for all materials and thicknesses

Material	LightWELD XR	LightWELD 1500 LightWELD XC
Material	LightWELD XR	LightWELD 1500 LightWELD XC
Stainless Steel	up to 6.35 mm	up to 4 mm
Galvanized Steel	up to 6.35 mm	up to 4 mm
Mild Steel	up to 6.35 mm	up to 4 mm
Aluminum 3 & 5 Series	up to 6.35 mm	up to 4 mm
Aluminum 6 Series	up to 3 mm	—
Nickel Alloys	up to 5 mm	—
Titanium	up to 5 mm	—
Copper	up to 2 mm	—

LightWELD Pre-Weld Cleaning

LightWELD XC and LightWELD XR provide pre-weld cleaning for stronger, higher-quality welds

Any contaminants can enter the weld pool and compromise weld integrity
Pulsed cleaning power up to 2500 W peak power evaporates undesired surface elements
Fast and effective removal of contaminants such as oxides, rust, paint, oil, or grease from surface without the use of chemicals or abrasives
Up to 15 mm of adjustable cleaning width with one pass

LightWELD Handheld Laser Welding and Cleaning System being used as a handheld laser cleaner

LightWELD Post-Weld Cleaning

LightWELD XC and LightWELD XR provide post-weld cleaning improves visual finishes

Post-weld cleaning removes soot, debris, or any sign of localized heating
Dramatically reduces time, cost and scrap
Create visually appealing welds while eliminating need for post-grinding
Up to 15 mm of adjustable cleaning width in one pass

LightWELD offers Welding & Cleaning in a Single System

LightWELD XC and LightWELD XR can switch from welding to cleaning in just seconds

Specially designed welding and cleaning nozzle tips for any joint configuration
Increased productivity using single system for multiple fabrication processes
Simply loosen the collet and insert a welding or cleaning nozzle, select the appropriate mode and the system is ready to clean or weld

Built-in Wobble Welding for Increased Productivity

Simple on-the-fly control of up to 5 mm of additional weld width with selectable frequencies
Creates highly aesthetic seams and welding of parts with poor fit-up
Wobble parameters are preprogrammed and can be saved by the operator and recalled immediately as needed
In cleaning mode, the wobble function provides adjustable cleaning scan widths up to 15 mm

Optional Wire Feeding Package

Wire welding capability extends laser welding applications to poorly fit-up parts
Used for low carbon steel, stainless steel, aluminum and non-ferrous metals and alloys
Wire feed speed range 40 – 600 cm/min (15 - 230 ipm)
Wire diameter capacity 0.8 to 1.6 mm ( 0.035''- 0.063'')
Wire feed tips: 0.8mm, 0.9mm, 1.2mm, 1.6mm
2x V-rollers and steel liners for hard wire , 2x U-rollers and Teflon liners for soft wire
Package includes wire feed unit, electrical connections, nozzle assembly and IPG Process Mode software

LightWELD Laser Welding & Cleaning Systems

Easy to Learn

Built-in factory presets for welding and cleaning reduce learning curves, new welders can be trained within hour and experienced welders realize an immediate increase to productivity

Highly Productive

High-speed welding that is 4X faster than TIG, with simple material preparation and minimal post-finishing, plus wobble welding and wire feed options for consistent high-quality results

Highly Capable

Easily weld and clean thick, thin and reflective metals with low heat input from < .040" (1.0mm) up to 1/4" (6.35mm) with minimal part distortion, improved visual appearance and increased overall part quality

	LightWELD Handheld Laser Welding	LightWELD XC Handheld Laser Welding & Cleaning	LightWELD XR Extended Range Handheld Laser Welding & Cleaning
Laser Type (Welding mode)	Air-Cooled Ytterbium Continuous Wave 1070 nm Fiber Laser
Laser Output (Welding mode)	1500 W Average Power, with 2500 W Peak Power Class 1 Red Guide Beam
Laser Output (Cleaning mode)	—	2500 W Peak Power Pulse frequency up to 50 kHz Pulse duty cycle up to 20%
Umbilical Cable	Utilities Bundle from Base Unit to Head including: Fiber Laser Delivery, Process Gas, Process Head Control Signals and Safety Interlock Circuits - Length: 5 m (16 ft) optional 10 m (32 ft)
Cooling	Air Cooled – No External Chiller Required
Weld Head	Handheld Wobble Welding Head Collimating Length 40 mm, Focus Length 120; Spot size 150 μm Incorporating Safety Control Sensors and Laser-on Indicator User-changeable nozzles for planar, internal corner, and external corner welds		Handheld Wobble Welding Head Collimating Length 50 mm, Focus Length 120; Spot size 60 μm Incorporating Safety Control Sensors and Laser-on Indicator User-changeable nozzles for planar, internal corner, and external corner welds
Weld Head Cleaning Nozzles	—	Set of three nozzles for wide-angle scanning
Spot Size	150 μm		60 μm
Wobble Length	Adjustable up to 5 mm
Cleaning Scan Length	—	Adjustable up to 15 mm
Process Gas	Argon, Nitrogen, Argon + CO2 mix For LHW-1500-5 Meter: Working Pressure 69-138 kPa, (10-20 psi) For LHW-1500-10 Meter: Working Pressure 103-207 kPa, (15-30 psi)
User Interface	Front Panel Controls of Laser Power, Mode, Wobble Length and Wobble Frequency: (Rotary knobs with digital display). Laser On/Off key Switch, E-Stop Button. - Status Indicator Lights
Computer Connection	Ethernet Connection to Web Page Interface Allowing Viewing/Adjustment of Process Mode Settings and System Status and Alarm Signal
Safety	Class 4 Laser Device. Customer responsible for standard ANSI Z136.1 safety precautions. System features include key for laser ON/Off, 2-step laser operation trigger (Enable and Fire), Part-head contact safety circuit, Facility door interlock circuit
Operating Environment	Storage temperature -20 to 60 °C. Operating range +5 to 35 °C
Ease of Aluminum Weld	Moderate		Easy
Single-Side, Single Pass Material Weld Capability	Stainless steel, mild steel, galvanized steel, aluminum up to 4 mm		Stainless steel, mild steel, galvanized steel, aluminum up to 6.35 mm, copper up to 2 mm
Facilities Requirements	Electrical: 220 V, 1 Ph, 50/60 Hz, < 30 Amp
Weld Base Unit (W x D x H)	316 x 641 x 534 mm (12.4 x 25.2 x 21 in)
Weld Module Weight	53 kg, (118 lbs)
Accessories	Safety Glasses, Power Connecting Plug, Ethernet Cable

LightWELD Support and Service

Contact our dedicated LightWELD support team by phone, email or the form on this page to:

Answer your questions
Request service
Order spare parts

Phone: +1 508.506.2877

Email: LightWELD@IPGPhotonics.com

Visit the LightWELD online support site to access:

User Manuals
Welding Mode Charts
Support Videos
Spare Parts Portal

Access Support Site

LightWELD Sales

Contact Sales:

Email: Contact-LightWELD@IPGPhotonics.com

Contact support

LightWELD Frequently Asked Questions (FAQ)

Is LightWELD really faster than MIG and TIG welding?

Yes, LightWELD travel speed is up to four times faster than traditional methods, fixturing is simpler or not necessary, and post-weld grinding or sanding is not needed or significantly reduced – all of which increases productivity while minimizing rework.

Is LightWELD really that easy to learn?

Yes, compared with MIG and TIG welding, either of which can take a lifetime to master, LightWELD is quick to learn, allowing new users to make high-quality welds in just a few hours.

The controls look confusing. How do I know what to adjust?

LightWELD comes preloaded with optimized welding parameters for the most common materials and thicknesses. You can adjust the power up or down to match your travel speed and desired penetration, and you can save those settings and recall them as needed.

Can LightWELD weld dissimilar metals or parts with different thicknesses?

Yes, you can easily weld dissimilar metals like copper to stainless steel or to aluminum, plus parts with different thicknesses across all weld joint types: tee, butt, corner, lap and edge.

What is the maximum material thickness that can be welded?

For stainless steel, galvanized steel, mild steel and aluminum, you can weld single-sided up to 4 mm and double-sided up to 10 mm – copper single-sided up to 1 mm and double-sided up to 2 mm.

What about vertical welding or upside down welding?

LightWELD excels at both vertical and upside down welding since there are normally no consumables and minimal spatter produced, making it safe and easy to weld in any position.

Is the laser beam constant or can it be pulsed?

LightWELD offers five modes of operation to match your needs:

Continuous wave - the laser is on constantly for maximum penetration and travel speed
Pulsed mode – laser pulses producing less energy for slower welding with less heat input
Tack mode – to create identical tack welds
Stitch mode – used for repeated tacking or overlap welds
High peak power mode – short bursts of high power used to penetrate reflective metals

What is the duty cycle?

You can run LightWELD at 100% duty cycle at the maximum 1500 watts of laser power.

What’s wobble welding?

Wobble welding oscillates the beam back-and-forth at various frequencies to produces wider seams and more aesthetic welds. It is also helpful for parts with poor fit-up. LightWELD comes with optimized, preprogrammed wobble parameters and allows on-the-fly control of up to 5 mm of wobble welding at adjustable frequencies up to 300 Hz.

Is there a datasheet?

Yes, you can download the LightWELD 1500 datasheet here.

Where can I see a demonstration of LightWELD?

You can sign up to register for a live demo here.

How do I buy LightWELD?

Click here to fill out a contact form and a LightWELD specialist will get back to you asap. If you would like to speak with someone now, please call (508) 506.2877

Overview

Overview Features Specifications Resources Options Software

Handheld Laser Welding and Cleaning Systems

Easy to Learn & Operate • Simple & Fast to Set Up • Consistent High-Quality Results

LightWELD Unbeatable Benefits

LightWELD - Turnkey Handheld Laser Welding & Cleaning Systems

EXPERIENCE LightWELD YOURSELF!

LightWELD - Less Heat & Distortion for More Productivity & Flexibility

“In my 41 years in the business, I have never seen a welder that allows beginners to make welds like seasoned pros!”

LightWELD - Factory Presets Ensure Optimized Welds & Cleaning

LightWELD is Fast & Easy to Set Up

Fast and Easy Setup

LightWELD Operator Safety Features

LightWELD Material & Thickness Welding Range

Material

LightWELD XR

LightWELD 1500LightWELD XC

Material

LightWELD XR

LightWELD 1500LightWELD XC

LightWELD Pre-Weld Cleaning

LightWELD Post-Weld Cleaning

LightWELD offers Welding & Cleaning in a Single System

"The travel speed and diversity of materials

that can be welded is unbelievable"

Built-in Wobble Welding for Increased Productivity

Optional Wire Feeding Package

LightWELD Laser Welding & Cleaning Systems

Easy to Learn

Highly Productive

Highly Capable

LightWELD

LightWELD XC

LightWELD XR

LightWELD Support and Service

Visit the LightWELD online support site to access:

LightWELD Sales

Contact support

LightWELD Frequently Asked Questions (FAQ)

Is LightWELD really faster than MIG and TIG welding?

Is LightWELD really that easy to learn?

The controls look confusing. How do I know what to adjust?

Can LightWELD weld dissimilar metals or parts with different thicknesses?

What is the maximum material thickness that can be welded?

What about vertical welding or upside down welding?

Is the laser beam constant or can it be pulsed?

What is the duty cycle?

What’s wobble welding?

Is there a datasheet?

Where can I see a demonstration of LightWELD?

How do I buy LightWELD?

Are You Ready to be Amazed?

LightWELD 1500
LightWELD XC

LightWELD 1500
LightWELD XC