Conference

Laser

F066: Getting Handheld Laser Joining Right in the Fab Shop: Best Practices From Setup to Process Control

  • Date

  • Time

  • Location

    N209-210

Presentations

Handheld Laser Welding in the Fab Shop: What to Get Right on Day One

3:00 pm – 3:30 pm Intermediate

Handheld laser welding is rapidly transforming fabrication shops by delivering faster travel speeds, reduced rework, and strong performance on stainless, carbon steel, and aluminum. As more job shops and OEMs evaluate these systems alongside traditional MIG/TIG (GMAW/GTAW) processes, it is critical to understand both the productivity benefits and the safety requirements associated with operating 1,000 W to 2,000 W Class 4 lasers. This session provides a practical roadmap aligned with ANSI, LIA, and AWS guidance for safely integrating handheld laser welding into real-world fab environments. Attendees will learn how to identify laser hazards, designate an LSO, establish a compliant laser‑controlled area, choose proper PPE, and implement a standards‑aligned written safety program. The session also covers shop‑floor best practices, such as managing reflections, controlling torch angles, and coordinating fume extraction, giving fabricators the confidence to adopt handheld laser welding safely while maximizing productivity.

The Effects of Critical Process Parameters on Aluminum Handheld Laser Welds

3:30 pm – 4:00 pm Intermediate

Aluminum is highly sensitive to process variation in handheld laser welding, where small changes in parameters can significantly impact penetration, porosity, cracking, and overall weld quality. This presentation from The Handheld Laser Institute examines the influence of key variables—including power density, travel speed, shielding gas selection, focal position, and joint fit-up—on weld performance and mechanical properties. Attendees will gain data-driven insights and practical guidelines to optimize process stability and achieve repeatable, high-quality aluminum welds in production environments.

Handheld Laser Welding of Aluminum: Challenges and Solutions

4:00 pm – 4:30 pm Intermediate

Aluminum presents unique challenges for handheld laser welding, including high reflectivity, thermal conductivity, porosity, and crack sensitivity. This session from Handheld Laser Institute will break down the root causes of these issues and provide practical, field-tested solutions covering equipment considerations, parameter selection, joint design, and inspection methods. Attendees will leave with actionable guidance to confidently deploy handheld laser welding for structural and production aluminum applications.

About the Speakers

  • Kyle Smith

    Lincoln Electric Co

    Biography

    Kyle G. Smith is the Business Manager of Laser Automation at The Lincoln Electric Company. He holds a B.S. in Mechanical Engineering from Ohio Northern University and joined Lincoln Electric in 2013. He has worked in laser processing since 2014, performing application development and designing laser welding machinery. He has led Lincoln Electric’s laser processing automation business unit since 2018 and frequently contributes at industry events and customer workshops.

    More Details about Kyle

  • Rex Alexandre

    The Handheld Laser Institute

    Biography

    Rex graduated from OSU with a BS and MS in Welding Engineering in 2016. His first introduction to handheld laser welding was in 2020 working on SpaceX’s Starship. What started as a personal curiosity and side project grew to an industry-leading HLBW program used to manufacture the world’s largest and most powerful space launch vehicle. As President of HLI, Rex is pushing the boundaries of HLBW through research and training.

    More Details about Rex

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