Manual instead of automated: While laser welding used to be firmly in the grip of robots, more and more human welders – especially in medium-sized companies – are now using handheld laser tools. Fine welds, minimal workpiece deformation, lower energy consumption and high precision: Manual laser welding offers many advantages. But it also poses significant challenges. "This is not for beginners," says Stephan Berekoven, a DVS (German Welding Society) welding specialist and head of internal sales at BSW-Anlagenbau GmbH in Everswinkel.
The company's literature points out that it is the "first company in Münsterland to be certified by TÜV for laser welding in accordance with DIN EN ISO 9601-1 521". This is a standard that covers welding of steel, and Addendum 521 specifically covers manual laser welding. Why did they pursue this certification? It was because of jobs like this: "A customer from the autonomous vehicle technology sector needed a solution for complex stainless steel components (1.4301) at short notice.

Using manual laser welding, we were able to respond quickly and flexibly – with precision, with low distortion, and with virtually no reworking. The process offers significant advantages in terms of time and cost, in particular for small batches, but also for larger orders. The high quality of the welds and the low heat input are what convinced us", answers Stephan Berekoven. The energy of the laser beam is guided to the weld site in such a concentrated and precise way that particularly fine welds are produced. However, welding with a handheld laser requires training and experience. "Our specialists have worked hard, because when it comes to manual welding, it's not just the technology that counts, but also the operator's skill."

Closing the gap

Andrew Taupitz, Managing Director of Taupitz GmbH & Co KG, a company based in Großenhain, Saxony that specialises in sheet metal forming, sees things the same way: "Especially when it comes to complex component geometries and hard-to-reach areas, conventional welding processes quickly reach their limits – we have recently experienced a clear example of this with a welded assembly made of thin stainless steel. Thanks to the minimal heat input, high weld quality, and the capability to adapt flexibly to the component at hand, we were able to fulfil the order precisely and efficiently, without any reworking. Manual laser welding closes the gap between automation and manual work."

Safety First

"Manual laser welding is a modern and flexible method that does not replace but complements traditional techniques such as TIG or MAG welding in many workshops," agrees Oliver Würth, a technical expert in welding and cutting at Air Liquide. The compact welding unit is very lightweight and straightforward to operate, making it ideal for complex components such as stainless-steel railings or fine sheet-metal structures. "The benefits are obvious: The weld is extremely precise, clean and very narrow. Of course, safety is paramount; you should always wear special laser safety goggles to protect your eyes." Working in a clearly defined area ensures that no one is exposed to the laser beam.

A case for (almost) all materials

The Fraunhofer Institute for Production Systems and Design Technology (IPK) knows exactly which materials can be welded with hand-held lasers: "Lasers can be used to quickly and easily join unalloyed, low-alloy and high-alloy steels, as well as weldable aluminium and nickel-based alloys. Titanium and copper alloys can also be processed. Typical applications are welding T-joints, overlap joints and corner joints, but the technique can also be used for I-joints," according to the institute's description of the process. "However, it is important that welding is embedded in a well-designed process, because even a flawless surface can hide defects. To prevent this, cross-sections and, where necessary, X-ray testing are recommended. This effort is worthwhile: with the right choice of parameters, the highest quality rating can be achieved,” emphasises Raphael Marquardt, Research Associate in Joining and Coating Technology at IPK.

All in all, this is an economically attractive process, but one that requires thorough in-house preparation and specially trained operators. Or, as Stephan Berekoven puts it: "Strictly for professionals!"

The new hotspot for welding and cutting professionals is The Ultimate World of Cutting and Welding – Urban Steel Expo, or USE for short. This new trade fair format will celebrate its first edition at the Messe Düsseldorf exhibition centre from 20 to 23 April 2027. More information: https://www.use-expo.de/

The Ultimate World of Cutting and Welding – Urban Steel Expo

With The Ultimate World of Cutting and Welding – Urban Steel Expo, or USE for short, Messe Düsseldorf has developed a new concept specifically tailored to the needs of the welding and cutting industry. This innovative platform blends technology, business and event experience, creating a new forum for dialogue and networking. From 20 to 23 April 2027, USE will make its debut, and every four years thereafter, the Düsseldorf Exhibition Centre will become an international hub for companies specialising in separating and joining technology, as well as related processes and technologies. With USE 2027 the traditional trade fair is being redefined. Technology, business, creativity and community merge into a single industry event. The new format will bring together global market and innovation leaders and showcase cutting-edge technologies.