Above: Made in the U.S., LightWELD laser welding machines are designed for high performance in both common and demanding welding applications.
March, 2026- Over the last few years, handheld laser welding has begun to fundamentally change the welding industry. Organizations like The Welding Institute (TWI) describe the increasingly popular process as an emerging technology due to the need for new standards and expanded training and education among users. IPG Photonics was among the first to bring the technology to a broader fabrication market when it introduced its LightWELD handheld laser welding system in 2020.
Engineered for ease of use and precision, LightWELD boosts productivity and reduces heat distortion. As the technology continues to gain traction, IPG Associate Product Manager for LightWELD Kevin Brecken says that “welding with light is about more than just buying a new tool.”
The fiber laser builder is focused on educating fabricators about how to unlock the technology’s benefits and avoid some common pitfalls. “Handheld laser welding is a game-changer for fabricators,” says Brecken. “But you have to understand how it works and what you are trying to accomplish. It’s about learning how to optimize a new process.”
Although laser welding demands less manual dexterity than MIG or TIG, it still provides plenty of room for mastery.
CHECKLIST
For fabricators, reasons to consider implementing the technology might include the need to improve weld quality, reduce post weld grinding or eliminate distortion problems. LightWELD can help companies train new personnel faster, reduce consumable and electricity costs, improve weld-to-weld consistency or increase turnaround.
“It’s important for job shops and contract manufacturers to understand that laser welding is not a one-size-fits-all solution,” says Brecken. “Not every operation will be able to replace all of their MIG and TIG welding with laser welding.”
IPG has seven demonstration trailers that travel across the United States and Canada to provide demonstrations of LightWELD. These mobile units allow potential customers to experience hands-on laser welding demonstrations at their own facilities.
“Whether a customer wants to see LightWELD in action firsthand or learn more about what it can do, we make it easy to get started,” Brecken says. “We often talk to customers about the importance of choosing an equipment champion and parts that are good candidates for laser welding. That means finding someone who is enthusiastic―ideally a welder or manager, who at least understands how to use the machine, how to maintain it and how to follow laser safety best practices. A good candidate part is anything that lends itself well to handheld laser welding.
LightWELD offers comprehensive built-in welding parameter sets for a wide range of materials while providing options for deep customization.
“We visited a fabricator in Wisconsin. They brought out a large part for an agricultural equipment application,” Brecken says. “It did not have the best fit-up. It required more technique and experience to weld it successfully. We walked through the shop with them and pointed out five or six other parts that were better suited to handheld laser welding, and recommended they start with those parts.”
Unlike MIG or TIG, LightWELD is not well-suited for wide gaps or poor part fit-up. Beam wobble modes and wire configurations help to bridge gaps but, for optimal results, laser welding requires tight, consistent joints.
Brecken recommends manufacturers launch a pilot program. To identify suitable parts, companies should look for light- to medium-gauge carbon or stainless steel parts with repeatable fit-up, high quality requirements and that are typically labor intensive for MIG or TIG welding.
LightWELD uses a concentrated beam of photons to create precise, high-strength butt, T-joint, corner, lap and edge welding.
RAPID WELDING
“One of laser welding’s biggest advantages is speed,” he says. “It’s four to six times faster than TIG and three times faster than MIG. LightWELD is based on the same fiber laser welding technology used in demanding automotive and aerospace applications. It’s fast, easy to learn and produces excellent welds.”
LightWELD is available in 1,000, 1,500, and 2,000-watt configurations. Suited for use with uncoated and galvanized steel, aluminum, nickel alloys, copper and titanium, the tool is gaining momentum among manufacturers of food and beverage equipment, automotive and HVAC components, and general fabricators.
While individuals can learn to use LightWELD relatively quickly, Brecken says there are nuances to the tool that make training essential. Preloaded parameters for different materials and user-friendly controls reduce some of the manual dexterity requirements when compared to arc welding, but a solid grasp of welding fundamentals can streamline the process.
“It’s another skill to be learned, not a replacement for skilled labor,” he says. IPG provides on-site training as well as virtual programs and resources.
IPG’s LightWELD technology allows for finer control in applications where distortion or spatter are unacceptable. Handheld laser welding technology is being used by metal artists and small job shops to global manufacturers for a range of materials and thicknesses.
“LightWELD is a modern solution that is already increasing throughput and lowering costs,” Brecken says. “It can open doors to new markets and it has the potential to position companies to serve new kinds of customers.”
IPG Photonics, 508/373-1337, lightweld.com
