Above: A charge-coupled device (CCD) camera ensures precision and automation in manufacturing tasks
October, 2025- High speed, efficiency and adaptability have made fiber laser welding technology an essential tool for manufacturers, especially companies that need faster throughput for tight tolerance parts. According to market research, fiber lasers are expected to account for 70 percent of new laser welding machine installations in 2025. The precision, noncontact technique is seeing an increase in automation as well.
AMADA AMERICA’s FLW ENSIS fiber laser welder addresses large-scale applications and is available in 3 kW to 6 kW models.
The FLWENSIS can bridge larger and uneven gap sizes while producing a clean, even weld.
“The serious lack of qualified welders in today’s market has prompted widespread adoption of automated fiber laser welding processes,” says Leonard Fioroni, laser welding application engineer for AMADA AMERICA INC. “As a result, companies are seeing productivity increases and higher quality parts.”
To better equip fabricators and job shops, AMADA GROUP organizations AMADA AMERICA and AMADA WELD TECH INC. provide the metalworking industry with a full range of fiber laser welder products as part of the company’s AMADA ONE philosophy, “providing customers a single partner for endless potential.”
An MM-L400A Laser Weld Monitor records infrared, visible and reflected radiation during a fiber laser welding process.
AMADA WELD TECH designs and builds single mode and multi-mode fiber laser systems engineered for medium-power ne welding, high-speed seam welding and precision micro welding of small components. Its LF Series, ranging from 100 W to 1 kW, can produce welds that measure in tens to hundreds of microns, making the equipment ideal for applications that dictate extreme accuracy. On the other end of the spectrum, AMADA AMERICA addresses large-scale applications with its FLW ENSIS fiber laser welder. Available in 3 kW to 6 kW models, this system delivers high-speed, high-quality welds that can’t be accomplished with conventional laser welding. The FLW ENSIS models can process stainless steel up to 12 mm thick and aluminum up to 8 mm thick.
“Fiber laser welding has experienced a strong upward trend over the last 10 to 15 years, driven by continuous technology advancements that expand both capabilities and opportunities,” says Mark Boyle, director of product engineering and applications for AMADA WELD TECH. “Our specialty lies in precision micro welding of materials such as steel, nickel alloys, titanium, aluminum and copper. These processes are essential to demanding applications in medical devices, batteries, electric vehicles, solar energy, electronics and automotive manufacturing—industries where weld quality and reliability are absolutely critical. When an application moves beyond micro welding into higherwattage sheet metal welding, that’s where our colleagues at AMADA AMERICA come in. The transition between our organizations is seamless, giving customers a single source for expertise across the full spectrum of welding—from the smallest medical component to large-scale sheet metal assemblies.”
Domed stainless steel medical guidewire (as small as 0.5 mm diameter).
In heavy-gauge applications, the ENSIS fiber laser welder is proving effective in industries such as commercial food equipment where products demand both speed and precision.
“It can be costly to finish stainless steel because it’s easy to damage,” says Fioroni. “Fiber laser welding significantly reduces the potential for errors. Server racks for data infrastructure projects make up a large portion of our business because suppliers want to process the work quickly. With our technology, a customer can perform laser spot welding and seam welding in one process, so it’s really advantageous for these types of products.”
In addition to differences in power, AMADA AMERICA and AMADA WELD TECH products offer a range of advanced features that enhance manufacturing capability and quality.
ENSIS is equipped with a patented rotating lens, which allows the laser beam to make circles in a small area as it welds. As a result, it can bridge larger and uneven gap sizes while producing a clean, even weld. Since heat input into the metal is optimized, the ENSIS achieves precise, defined edges with minimal material deposits. AMADA WELD TECH employs a similar technique using galvo beam steering to oscillate the beam and expand the melt pool to improve welding results.
PROCESS MONITORING
“At AMADA, we employ AITAS—Artificial Intelligence Teaching Assist System—with ENSIS to compensate for any deviation in the welding path,” says Fioroni, “and we use a chargecoupled device (CCD) camera, to ensure precision and automation in manufacturing tasks.”
The CCD camera observes the part and compares it to the pre-programmed path. If differences are detected, it automatically adjusts the robot’s weld trajectory. In addition to weld consistency, AITAS reduces setup time and the need for manual adjustments, making transitions between jobs faster. Compensated weld points are stored for future production runs.
AMADA WELD TECH Delta Series workstation integrated with an LF Series REGIONAL fiber laser welder.
AMADA WELD TECH employs active weld process monitoring. “We’ve led the industry in resistance weld monitoring for decades, but more and more customers are now asking about laser weld monitoring,” says Boyle. “It’s part of a growing awareness across manufacturing —companies are realizing the value of data for driving process improvement. Our laser weld monitor such as the MM-L400A provides real-time quality control by capturing and analyzing the thermal characteristics of the weld process to detect potential defects and help maintain process consistency.”
It can monitor a weld’s thermal signal, visible light from the plume and back reflection to provide waveforms that can be used to set quality limits and detect production defects such as gaps, surface contamination or lack of cover gas. In addition, the unit provides critical data for analysis for process and manufacturing improvements.
“Our organizations build different machines for different applications,” says Boyle. “But there is a common denominator: Our systems are configured for ease of use and maximum productivity. It can be as simple as pushing a button to start the weld cycle.”
Fioroni agrees. “Our goal is to make our laser fiber welders as easy as possible to use,” he says. “These multi-process machines can move seamlessly between different material types whether it’s stainless, cold rolled steel or aluminum. An operator just calls up the parameters. They don’t need to make any changes.”
Both Fioroni and Boyle expect adoption of fiber laser welders to continue to grow for reasons that vary from companies looking to upgrade legacy equipment, meet sustainability requirements with ecofriendly equipment or automate welding processes.
“New developments in AI and robotics will also contribute to that growth,” says Fioroni. “I believe it’s the future of welding.”
AMADA WELD TECH INC., 626/303-5676, amadaweldtech.com
AMADA AMERICA INC., 714/739-2111, amada.com
