LIGHTWELD

Handheld Laser
Welding & Cleaning System

© 2022 IPG Photonics

 IPG By the Numbers

2/3rds
40,000 6,000 OF FIBER LASERS
+100K E M P L O Y E E S MANUFACTURED WORLDWIDE
DEVICES SHIPPED IN 2019
INSTALL BASE

FOUNDED NASDAQ:
40B
1990
POUNDS LESS GLOBAL CO2

IPGP
EMISSION WHEN OPERATING
IPG LASERS COMPARED TO
OTHERS (2011-2018)

400 PATENTS 2 4 T E R AWAT T H O U R S

450 PENDING OF ELECTRICITY SAVINGS SINCE 2011

© 2021
2022 IPG Photonics - Confidential and Proprietary
2
 WORLDWIDE APPLICATIONS RESOURCES

Allershausen, Germany
Detroit, MI Toronto, Canada Daejeon, Korea
Fryazino, Russia
Burbach, Germany
Minneapolis, MN
Moscow, Russia
Bristol, UK Shanghai, China
Santa Clara, CA
Gliwice, Poland
Davenport, IA Marlborough, MA
Milan, Italy
Beijing, China
Anaheim, CA
Oxford, MA Istanbul, Turkey
Santa Catarina, Mexico
Delhi, India Wuhan, China

Birmingham, AL
Shenzhen, China

Yokohama, Japan

• LASER SOURCES • VISION SYSTEMS

• BEAM DELIVERY • 3D SIMULATION
• LASER SYSTEMS • DFM/DFA ANALYSIS
• METROLOGY • VARIATION SIMULATION

26
CUSTOMER APPLICATION
CENTERS WORLDWIDE
(8 IN USA)
PhD APPLICATION São Paulo, Brazil

SPECIALISTS
© 2021
2022 IPG Photonics - Confidential and Proprietary
3
 Revolutionizing the Laser Industry
Traditional Lasers

Ultra High Power

Carbon Dioxide (CO2)
Continuous Wave (CW) Lasers

High Peak Power Lasers with

Quasi CW (QCW) Option

Adjustable Mode Beam and

QCW Lasers

Lamp-Pumped Nd: YAG High Power Nanosecond Pulsed

Pico & Femtosecond Pulsed

 Expensive  Inefficient  Higher Productivity  Efficient

 Bulky  Frequent Maintenance  Compact  Minimal Maintenance
 Unreliable  Costly Consumables  Reliable  No Consumables
 Difficult to Operate  Not Scalable  Robust  Scalable

© 2022 IPG Photonics - Confidential and Proprietary

Materials Processing

GENERAL
MANUFACTURING
& OEM

AUTOMOTIVE
CUTTING WELDING BRAZING DRILLING
HEAVY INDUSTRY

SEMICONDUCTOR & ELECTRONICS

AEROSPACE

ADDITIVE MANUFACTURING

CLADDING ADDITIVE MARKING SURFACE

MANUFACTURING TREATMENT

© 2020
2022 IPG Photonics - Confidential and Proprietary
5
 LightWELD
An Alternative to MIG and TIG Welding

Handheld Laser Welding is:

 Faster – Less prep and shorter weld time

 Higher Quality – Less post weld grind/clean

 Less Heat – Less part distortion and damage

 Easy to Set up – Unbox and assemble in minutes

 Easy to Learn & use – High-quality welds in just a few

hours for pros and novices
 LightWELD
An Alternative to MIG and TIG Welding

TIG welding:
Traditional Welding LightWELD Laser • High heat input – part distortion
Methods Welding • Extensive finishing required
• Difficult on thin metals
Speed Average Up to 4X Faster than TIG • Limited on dissimilar thickness
Consistent high-quality
Quality Depends on user experience MIG welding:
results
• Consumable wire
Learning Curve Steep Quick and easy • Cleaning & beveling
• Work angles challenging
Material Limited with
Wide range with no set up
Flexibility consumables changes
Distortion &
High Very low LightWELD:
Deformation
• Dramatically faster
Heat Affected
Zone
Large Small • Easier to learn
• Higher-quality results
Wobble Yes- up to 5 mm - Less distortion
NO
Welding additional weld width
- Easier finishing
 LightWELD is Faster

Example: 0.134” (3.4 mm) Low Carbon Steel

Butt weld Tee Weld
MIG Weld: 24.6 sec 27.9
TIG Weld: 41.4 sec 50.3
LightWELD: 20.8 sec 19.7

Note: TIG process typically used for thinner metals and

stainless due to lower heat distortion and increased control

LightWELD Speed Advantages (Thin) LightWELD Speed Advantages (Thicker)

 Shorter “Beam On” Time  Much shorter “Beam On” Time
 No gap setting and adjustment time  No edge beveling grinding
 No post weld grinding  No cool down time between passes

“ Much faster and easier than TIG ”

LightWELD is Higher Quality

Better / Cleaner Weld

“We had been turning down jobs for
thin copper and aluminum – with this
we could do them

Less Heat Related Defects

“The low distortion is unbelievable”

Requires Zero, or Little Finishing

“…a quick kiss on both sides [weld
edges] and its done”
 LightWELD is Higher Quality

LightWELD Weld Cross Section

Better / Cleaner Weld
“We had been turning down jobs
for thin copper and aluminum –
with this we could do them”

Less Heat Related Defects

“The low distortion is unbelievable”

Full penetration, Low Porosity

6.3 mm (.250 inch) Stainless Steel

Single-Pass Butt Weld
 Improved Dimensional Control

Also Simplifies Setup

TIG Welding Laser Welding

Added gap between parts

2X speed shown
LightWELD Simple Installation

Simple Installation and Operation

• 220 V, 20 A, single phase power
• Standard welding gas bottle
• Compact, portable welding unit:
• (LxWxH) 641x316 x534 mm, 53 kg
(25.2"x12.4"x21", 118 lbs)
• No consumable electrodes required
LightWELD Welding Head

Integrated Head Design

• Beam forming optics (40 / 120 mm)
• Wobble (scan) function (5 mm)
• Gas delivery
• Part-present sensing circuits
• Focus adjustment via nozzle selection

IPG Weld Head Features

• 2- Position Trigger (Safety/Gas – Weld)
• High-brightness guide beam on first trigger position
• Laser-On indicator
• 5 m (16 ft) single wrapped umbilical
• 10m (32 ft) Optional
 LightWELD Laser Source

IPG Custom Designed Fiber Laser Source

• 1500 W average, 2500 W peak output power,
• Highly reliable – Zero maintenance
• High wall plug efficiency

IPG Custom Laser and Head Controller

• Tightly integrated total system control
o Laser , Head, Gas Control, Safety
• Simplified front panel interface
• Minimized component count for space and reliability

High-Efficiency Air-Cooled Base Unit

• Eliminates need/cost for water cooling
• Increases overall system reliability
• Increases portability
 LIGHTWELD is Easy to Use

Part Preparation (Up to 4 mm single side)

• Position parts with zero gap

System Setup
• Pre-defined material/thickness process modes
• Ready to go
Welding Process
• Draw head along seam in smooth motion
Save Parameters
• Create new stored mode for rapid recall

Does Not Require Years of Skilled Craftsman Training

 Stored Process Modes

LightWELD – Programmability
• Storage of 74 process recipes
• Simple recall – sets all parameters
• 20 Customer-programmed modes
- Programmed by your welding expert
- Usable by welding novice
• 54 IPG Pre-Set Modes
- Programmed by IPG’s laser experts
o Typical materials & Thickness
- Fast welding startup most jobs
• Adjustable and savable by your
welding expert
 Unique Laser Welding Applications

Thin-to-thick
Thick material acts as heatsink for MIG & TIG
Overlap
Thick to Thin

Dissimilar
Metals

10 mm Mild Steel Thin Copper

Dual-side weld, one pass each
side, no bevel preparation
 LIGHTWELD Welding Examples

Stainless Steel Flange Weld

.120” deep (3mm) flange welded to

stainless steel tube

Aluminum Lap Joint Spot Weld

.080” (2 mm) Top Plate, to .040” (1 mm) Base Plate

Shooting through thick piece and stopping within thinner

bottom piece

Laser controls ensure uniformity of each weld

Single Button Recipe Selection to Switch Between Materials

 LIGHTWELD Examples

Fillet weld on copper pipe to flange

Aluminum I Beam (Clean & Weld)

.25” (6 mm) Aluminum 6061

Laser cleaning pass followed by butt weld

Single Button Recipe Selection to Switch Between Materials

 LightWELD

Handheld Laser Welding with Pre and Post Weld Laser Cleaning

High-Speed Laser Welding

- Fast weld time and fast set-up
- Low heat input for low part distortion
- Easy to learn & use – even novices make great welds

Pre-Weld Surface Preparation

- Improve weld quality by removal of contaminants
- Pre-clean allows more consistent and repeatable welds

Post-Weld Polishing
- Remove soot, weld-related debris and heat discoloration
- Accelerate or eliminate further finishing steps
- Eliminates abrasives and toxic chemicals
 LightWELD
Laser Welding and Cleaning in a Single Tool
LightWELD 1500
 1500 W High-brightness beam for thick, thin and
reflective metal welding
 Welding head and 4 nozzles for different joint types
 CW, Pulsed and Wobble Operating Modes
 Pre-set welding modes for fast parameter setting
 Air Cooled – Compact, Single Unit

LightWELD XC and LightWELD XR

All the functionality of the LightWELD 1500
PLUS
 High frequency pulsed laser mode 2500 W pk power
 Wide (15 mm) scan field for high-speed coverage
 Weld head nozzle cleaning attachment with 3 tips
 Pre-set cleaning mode software
 LightWELD XC Pre Weld Cleaning

Pre-Weld Cleaning reduces spatter, reduces potential for weld voids, gives higher
weld strength and quality, with greater consistency and repeatability

Pre-Weld Cleaning Typical Examples:

• Stainless Steel – Removal of grease & oil

• Aluminum – Removal of excess oxide

• Mild Steel – Removal of rust

• Galvanized Steel – Removal of zinc

 LightWELD XC Full Welding Cycle
Switch back
Pre-Weld to cleaning
clean
nozzles to remove
and nozzle
rust.
process modetoSecond
removing soot
pass
for wire and weld-related
if necessary
welding debrisparts
for corroded
 LightWELD XC & XR Post Weld Cleaning

Remove soot, weld-related debris and discoloration

Stainless Steel, 2 mm Aluminum 5000, 2 mm
Standard Laser Weld
Laser Wire Weld
Laser Wire + Pre Clean
Weld

Laser Wire Weld

+ Pre & Post Clean

Laser Weld + Post Clean

 LightWELD Product Family

LightWELD LightWELD XC LightWELD XR

Handheld Laser Welding Handheld Laser Welding Extended Range Handheld
& Cleaning Laser Welding & Cleaning
LightWELD Product Family
 LIGHTWELD Product Family

LightWELD 1500 LightWELD XC LightWELD XR

Welding Power 1500 W
Wobble Width 5 mm
Wire Feed compatible Yes
High Frequency Pulsed Cleaning Peak Power N/A 2500 W 2500 W
Cleaning path max width N/A 15 mm (0.6") 15 mm (0.6")
Number of Materials with Stored Process Modes 5 5 9
Spot size on target 150 um (0.006") 150 um (0.006") 60 um (0.0024")
Ease of Aluminum Weld Moderate Moderate Easy
Typical Max Single Pass Weld Thickness
4 mm (0.040") 4 mm (0.160") 6.35 mm (0.250")
Steel and Aluminum 3XXX, 5XXX
Typical Max Single Pass Weld Thickness
3.0 mm (0.120")
Aluminum 6XXX
Typical Max Single Pass Weld Thickness
5.0 mm (0.200")
Titanium an Nickel Alloys N/A N/A
Fiber Cable Length Options 5m (16 ft) or 10 m (32 ft)
Facilities Requirements Electrical: 220 V, 1 Ph, 50/60 Hz, < 30 Amp
Weld Base Unit (W x D x H) 316 x 641 x 534 mm (12.4 x 25.2 x 21 in)
Weld Module Weight 53 kg, (118 lbs)
Accessories Safety Glasses, Power Connecting Plug, Ethernet cable
 LightWELD Operator Support Videos

Laminated Process Mode Chart

QR Code opens
Support Web Page

Serial number login

Access to support
downloads and videos
• Initial Set Up and System Overview
• Program Modes and Control Adjustments
• Laser Welding Basics and Parameter
Settings
• Computer Control for Customized Settings
• Safety Information and Procedures for
Safe Operation
 LightWELD – Next Generation Welding

Become a leader in next-generation

welding technology, and add your
experience to these early users:
“Welding with clean outside corners is huge. This gives us
almost-finished product with almost no follow on process”

“Can’t believe the travel speed - “Gave a great weld…

phenomenal” Perfect penetration”

“Travel speed and diversity of materials that can be welded

is unbelievable”

“Set up is minimal – the set up time unbelievable – we don’t

get paid for setup”

“Once a process is dialed in even a lower skilled worker

can get results – Great looking welds”
THANK YOU