Laser welding has become an established and widely adopted manufacturing process across numerous industries due to its precision, efficiency, and adaptability. Recognized for delivering high-quality, consistent welds with minimal thermal distortion, it has become a standard in sectors such as automotive, aerospace, electronics, and medical device production. We have seen different advancements in the last years to cover the new requirements of the industry. On one hand, the on-the-fly laser welding, which is an advanced manufacturing technique that enables precise and high-speed joining of components while they are in motion, making it ideal for automated production lines. This process uses high-powered lasers, often combined with real-time vision systems and motion tracking, to dynamically adjust the weld path and parameters as the workpiece moves. On-the-fly welding offers several advantages over traditional stationary methods, including reduced cycle times, improved alignment flexibility, and seamless integration into continuous manufacturing processes. On the other hand, handheld laser welding, which is a versatile and user-friendly technique that combines the precision of laser technology with the flexibility of manual operation. Unlike traditional welding methods, handheld laser welders produce clean, high-quality welds with minimal heat-affected zones, reducing the risk of warping or material damage. These systems are lightweight, easy to operate, and require minimal setup, making them ideal for small-batch production, on-site repairs, or applications involving complex or hard-to-reach joints.
Both new technologies demands new solutions in sources, laser heads, laser safety elements and process monitoring systems. We will discuss about the latest developments and remaining needs with the whole supply chain in this online meeting.
Rinaldo Rigon, PhD in Industrial Engineering, is the Technical Manager and Welding Coordinator at ECOR International and Industrial Delegate to Technical Commission IV (Power Beam Processes) of the IIW - International Institute of Welding.
Vision on-the-fly: An Open Interface for Real-Time Process Control of Remote Laser Welding
Cutting-Edge Techniques for Laser Welding Thick Copper Busbars
Marc Hummel studied Mechanical Engineering at RWTH Aachen University and received his M.Sc. diploma from RWTH Aachen and Tsignhua University in 2018. From 2018 to 2024 Marc Hummel worked as Research Assistant at the Fraunhofer ILT in the field of laser beam welding applications where he finished his PhD end of 2024. In 2024 he joined TRUMPF as Business Development Manager
Pasquale Franciosa is Professor and Head of the Laser Beam Welding Lab at WMG, the University of Warwick. His cutting-edge research in advanced laser welding focuses on laser-to-material interaction, process modelling, sensor fusion and application of machine learning techniques. A highly recognized expert with over 100 publications and several awards, his expertise includes dynamic beam shaping for tailoring weld microstructure and controlling melt pool. He leads several major industrial and research-funded projects globally.
