What Is a Good Laser Welder? The Complete Buying Guide

Laser welding is an innovative technology that is transforming the welding process. It is challenging traditional methods with its incredible speed, precision, weld quality, and ease of use.

As it is a new technology, buyers need to understand what a good welder is and what to look for while buying one. They need to know where they can use the laser welding machine, and whether it is suitable for the applications or not.

We’ve compiled this comprehensive laser welding guide that will help you in selecting the best laser welding machine. We will discuss important factors, technical terms, and other details to assist you in the buying process.

xTool MetalFab Laser Welder and CNC Cutter

Your All-in-One Laser Welder for Metalworking!

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When Do You Need a Welding Machine?

Before you buy a welding machine, you should know whether you need it or not.

A welding machine is needed when you want to create a strong or permanent bond between metals or metal pieces.

It isn’t a regular bonding method; instead, it fuses both metal pieces and allows their molecules to flow and create a permanent bond on cooling. If the metal pieces are perfectly welded, it works like a single metal piece, offering incredible strength.

In any application that requires permanent joining of metals, a welding machine is what you need. You can use it for multiple purposes and occasions.

Here are some applications where you may need a welding machine.

Manufacturing

Welding is commonly used in manufacturing. Any product that requires joining metal pieces, welding is an essential process. Be it appliances, industrial equipment, machinery, etc.

It is preferred for the structural integrity of the object. It helps in creating robust frames and structures that last a long time. Due to its high strength, it can even bear mechanical stress.

If you want to manufacture any product that requires the joining of metals, you really need a welding machine. Suppose you want to make a metal fire pit; a welding machine can help you join all the pieces together.

Metal Fabrication

Metal fabrication is a very common example of welding. It involves making metal structures. Welding is required to join metal pieces to create the structure.

The bond created by welding is extremely strong. It ensures high strength, and the structure can withstand heavy loads, vibrations, and stress.

For making water or fluid vessels, such as tanks, welding is used to create seamless joints between metals. It connects metals together to form pipes and vessel bodies that do not leak. If you want to make items like these or step into metal fabrication, you need a welding machine.

Metal Furniture

People who make metal furniture, such as metal tables, sofas, beds, etc., need a welding machine to create the frame, structure, and the whole item.

A welding machine helps in creating joints that offer incredible strength. They can bear the weight and even offer more strength than the metal itself.

For making or repairing furniture items, you need a welding machine.

Metal Décor Items

Metal décor items are in trend. Often, pieces require joining, and that’s where you need a welding machine.

If you own a small business that creates metal decorative items, you should have a welding machine. It opens up limitless possibilities for products you can make.

You can make sculptures, wall art, lanterns, lights, chimes, wind spinners, vases, tables, shelving, etc.

Metal décor artists who create sculptures from scrap also need a welding machine to join pieces.

Automotive

Welding is heavily used in the automotive industry. It plays an important role in the manufacturing, assembling, and even repair of vehicles.

Firstly, the structure of the body is put together through welding. The metal sheets are joined on the chassis to give it the required shape. The frame of the car is made robust by joining the components via welding.

After creating the whole structure, components are also assembled through welding. For instance, the exhaust system, engine blocks, hinges, door hardware, etc.

Thus, welding is a fundamental process used in automotive manufacturing and repair. If you work on automotive repairs and redesigning, a welding machine is a must-have. Even if you do modifications on vehicles, you need welding machines.

Metal Repairs

Repairing metal bodies or pieces requires welding. When metal pieces are dislocated or broken, welding helps in joining them.

Be it home repair, automotive repair, industrial equipment repair, or anything else, you need a welding machine for that.

There are endless repair options. For instance, metal furniture, doors, handrails, fences, car panels, frame repair, etc.

Metal DIY Projects

For DIY lovers, a welding machine is a necessity. They can unleash their creativity and turn their ideas into reality.

A welding machine allows them to make almost anything by joining metal pieces. They can make metal signs, art pieces, furniture, a workbench, or almost anything.

If you work on DIY projects, make new items, and try new ideas, you should buy a welding machine.

How Is A Laser Welder Compared to Other Welding Machines?

Let’s compare laser welding with TIG and MIG to understand how different it is in various aspects.

Heat Affected Zone (HAZ)

In other welding methods, such as MIG and TIG, the heat generated in the welding process affects a wider area. The heat-affected zone is extremely widespread, which could affect the surrounding area and result in warping, softening, cracking, bending, or other unwanted damages and changes.

For instance, if you are welding metal sheets, you weld in a line where you want to join both pieces. However, due to the high heat conduction of metals, the heat from the work area travels to the surrounding area. If the heat exceeds the temperature of the surrounding area near the melting point, the material could bend and deform its shape.

Even if you don’t see any visible change because of high HAZ, there could be changes in the mechanical properties. The material could become harder or more brittle. It could become soft and weak. Similarly, the heat can reduce the stress-bearing capacity and toughness.

There are methods and techniques to reduce the heat-affected zone, but still, the HAZ is wider compared to laser welding. In laser welding, it is possible to focus on a tiny area. The beam of the laser is extremely thin and the speed is incredible.

That’s why only a minimal area is affected. It is much safer compared to other welding processes. Only the work area is in focus, and the surrounding area remains intact.

Speed

All arc welding processes require time for a perfect weld. Welders hold the stinger or torch in hand and move slowly, such as a few inches per minute. It is required to fuse the metal pieces together and ensure a meticulous weld.

If the welder tries to do it in a hurry, the material will not fuse properly. The resultant joint will be weak. Other than that, there could be imperfections and other issues in the welding.

TIG is a slow welding process. The welder has to go slowly for a clean and quality weld. Moreover, it is important to work at low heat input to control HAZ. It is usually done at 6-8 inches per minute.

MIG is a bit faster compared to TIG. Welders can do 15-20 inches per minute. It is an excellent option for high-volume welding.

However, laser welding is faster than all arc welding and other types of welding methods. Usually, laser welding machines offer 3-10 times more speed than TIG welding and can easily cover 5-10 meters per minute.

That’s the reason industries are shifting to laser welding. It is an ideal option for fast welding, which eventually improves productivity to a great extent.

Because of the high speed of laser welding, it does not allow the heat to travel to a wider area. Which is a reason for low HAZ.

Precision and Quality

If we compare traditional welding methods, TIG welding is an excellent choice when it comes to precision and weld quality. It’s extremely precise because of the non-consumable tungsten electrode, controls, and filler material.

The welder can precisely control the heat, material deposition, and the weld quality. The final weld joint looks clean and aesthetically pleasing. There is no spatter or uneven weld surfaces.

MIG is not as good as TIG in precision and quality, but it’s better than SMAW. It is fast, which is the reason it is difficult to control. The weld quality highly depends on the weld, and the weld joint is not as clean as TIG. It requires cleaning and grinding after the welding process.

Laser welding is better than all of these. Its precision and quality are top-notch. The laser beam is so thin that it can create a narrow weld that is smooth and clean. The joint looks even and aesthetically pleasing. Therefore, laser welding is preferred for intricate jobs where weld quality and cleanliness matter a lot.

Automation

Among traditional welding methods, MIG is quite easy to automate. It can be fixed to a robotic arm, and the automatic wire feed works very well to fill the gaps. It is a great option for automation.

TIG is also automated where it is required. Applications where MIG can’t work, then TIG is the next option. However, it is a bit complex to automate. It is difficult because the robot handles the TIG torch from one side, and a separate wire feeder is required.

Laser welding is the ideal candidate for automation. It ticks all the boxes, such as high speed, precision, and ease of handling. It’s perfect for making automated, delicate welds. Automating laser welding is easy. The laser head or torch is attached to a CNC machine or robotic arm, and it does the job.

Operational Cost

Here comes the most important part for businesses, the running cost of welding methods.

MIG welding requires a consumable wire and shielding gas. Users need to bear the cost of these. However, it is a fast process, which is why the cost of welding an inch is less compared to TIG. Among traditional welding processes, MIG is a cost-effective option.

TIG is a bit expensive. It uses a non-consumable tungsten rod but can also require a filler material. Secondly, the shielding gas required in the process is pure Argon, which is a bit expensive.

It’s a slow process compared to MIG, so the cost of welding per inch is a bit higher. Moreover, the maintenance cost and other consumables, such as glass lenses and ceramic cups, make the process expensive.

Laser welding is the most cost-effective option among all. Firstly, it is an extremely fast process. It can handle high volume at a very low cost. It does not always require a filter material, but even in that case, it is still cheap.

Complexity

MIG welding is considered the easiest welding option in traditional welding methods. It is beginner-friendly, and users can achieve perfection in less time. That said, the labor required is also inexpensive.

TIG is a bit complicated and requires years of experience for perfection. It requires highly skilled labor to get the job done. Both hands are involved in the process, which is why it takes time to achieve perfect welds. The labor cost is also higher than MIG and SMAW.

Laser welding is much easier compared to TIG and MIG. Workers can easily achieve excellent joints using a laser, but in most cases, it is handled using a CNC or robot. It requires skilled labor and technicians, but they can learn the process in less time. The primary job is to select the right parameters, such as power and speed, and the rest becomes easier.

What Makes a Perfect Laser Welder?

While selecting a laser welder, you have to consider a few things to pick the right machine according to your needs.

Here are a few things that make a perfect laser welder.

xTool MetalFab Laser Welder and CNC Cutter

Your All-in-One Laser Welder for Metalworking!

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Software

Traditional welding methods do not require any software. They have control knobs on the machine that allow you to set the desired parameters.

But laser welding is different. The machine requires software to operate. And this is what technicians need to master.

The software defines the operability of the machine. Firstly, it should be easy to understand and use. Look for beginner-friendly options.

Nowadays, welding machines have simple software that has preset parameters for different materials. It makes setting the right parameters a breeze and reduces the chances of errors.

Users just need to upload the design for CNC welding or use the handheld laser. Some machines are also equipped with AI assistance that helps them generate designs quickly.

Welding Modes

It would be great if the laser welding machine could be operated in multiple modes. Common welding modes are Continuous Welding, Spot Welding, and Pulse Welding. If the machine is capable of working in all these modes, it opens doors to endless possibilities and creativity.

It makes the machine more versatile and allows it to work on a wide range of objects and projects without having multiple welding machines.

Compatible Materials

Every laser welding machine works on limited metals. Before buying a machine, it is important to know the materials you can weld with the machine.

Ideally, it should support a wide range of materials, such as stainless steel, aluminum, carbon steel, nickel alloy, brass, magnesium, etc. The more it can support, the better it is. You’ll be able to work on a wide range of welding projects.

Beam Quality and HAZ

For excellent precision, the laser beam should be narrow. The laser spot should be small to concentrate the energy in one place. It ensures targeting the spots and minimizing the heat-affected zones.

Laser machines often specify the expected HAZ. For the best results, it should be in a small fraction of an inch.

It is necessary to understand and note. Minimal HAZ prevents overheating of the surrounding area and eliminates the excessive cooling period. You can also work on delicate objects with perfection.

Speed and Control

Laser welding is extremely fast, but to get a better idea, you should check the maximum speed. The speed is mentioned in the specifications. Check out this value to get an idea of how fast the machine is. Usually, these offer more than 5X the speed of TIG welding.

The second important thing is control. This is what makes the machine easy to use and controllable according to the desired results. Ensure you can easily set the speed, power, and other parameters without any hassle.

Modern machines are also equipped with a small smart touchscreen panel where you can select the variables. The preset options and saved settings make the process quicker, easier, and error-free.

Compatible Thickness

Every laser welding machine has limitations on the thickness of the material. You have to understand the range of material thicknesses it can handle.

Laser welding isn’t for extremely thick material. It is suitable for thin to medium materials for welding. Some machines can weld materials up to several millimeters in a single pass.

The ability to weld thick materials depends on the wattage. The higher the wattage, the more heat it can generate and weld thicker materials. Check the wattage of the machine and the range of the thicknesses it can weld.

Cooling System

Laser welding machines require a cooling system to prevent excessive temperature of the chips or the machine itself. When the temperature goes extremely high, it could damage the chips, disturb the output laser, and ruin the weld quality.

It is necessary to control the temperature of the laser machine. For this, multiple methods and techniques are applied. Firstly, the chip should be equipped with advanced technology to regulate the temperature with the cooling systems. It allows the machine to work even in extreme temperatures.

The cooling system involves a high-performing heat dissipation system. With the help of large heat sinks, it dissipates the heat generated by the chips. It regulates the temperature. Secondly, fans are also installed in the machine. They work automatically when the temperature is raised from a certain level.

If the welding machine has an excellent cooling system, it will ensure stable results and a longer lifespan. Otherwise, it will require frequent maintenance and might not work in extreme temperatures.

Gas Control and Saving

A shielding gas could be required in the welding process, not always, but often. That’s why the welding machine should have a gas control system. It automatically provides the gas needed for the welding process. It adjusts the pressure and ensures excellent welds.

Advanced welding machines are also equipped with a gas-saving feature. It reduces the gas consumption in the welding process. It could further reduce the running cost of the machine.

Safety Features

Laser welding machines require more safety features than other welding machines. The reason behind this is the laser, which could be dangerous if not controlled properly.

Firstly, the machine should be certified by different regulatory bodies, such as CE, FCC, and FDA, to meet the safety and quality standards. Then, users can use the welding machine without any worries.

The machine should have an emergency stop button to stop the machine immediately if there is any issue. It should be equipped with an electrical safety design to prevent sparks and electrical failure. Real-time temperature monitoring is also important to prevent the machine from overheating and keep the machine and user safe.

If there is a CNC machine as well, you need some extra safety features. For instance, the CNC machine should have a laser filtering lid and chamber to prevent the laser from going outside. The machine should not start if the lid is not closed or the exhaust fan is not connected.

Versatility

Laser welding machines available in the market can also do cutting, metal cleaning, and rust removal. The same laser is used for multiple purposes.

It is better if your laser welding machine can also cut metal sheets. It would be great if it could remove contaminants from the metals and get rid of the rust. Thus, the same machine will give you more opportunities.

For instance, if you want to make a metal fire pit, you can use the laser machine to cut the metal sheets into the desired sizes, patterns, and shapes. Then, you can join them through welding.

Best Laser Welder for Metalworking: xTool Metal Fab Laser Welder & CNC Cutter

xTool MetalFab laser welder is an all-in-one metal workshop. It has made metalworking extremely simple and accessible with an industrial power machine in a garage simplicity. It’s a unified machine for laser welding, cutting, and cleaning. From DIY to small business, it is a perfect option for your needs.

It is engineered for extremely precise welding of stainless steel, carbon steel, aluminum, brass, titanium, magnesium, nickel alloys, galvanized sheets, etc. It can weld up to 5mm thick materials in one pass. The best part is its magnificent speed, which is 8 times faster than TIG welding.

It’s equipped with user-friendly software that makes welding, cutting, and cleaning a breeze. Users can upload the design, select the desired parameters, and let the machine do its job.

It offers 108+ preset options to select quick settings for different materials. Its AI also helps in making designs with just prompts. And the smart touchscreen makes everything effortless.

Here are a few notable features of xTool MetalFab laser welder.

CNC Cutting

The machine offers CNC cutting, which means you just need to upload the design, and it cuts the desired shape on its own. It can cut materials up to 0.39 inches (10mm) thick in a single pass and offers flawless and smooth cuts. It offers an incredible cutting speed of 15.75 inches per second, which completes jobs in minimal time.

It’s equipped with VibeFreeCut (adjusts automatically according to the shape of the object without vibrations), FlexiTrack (adjusts optimal focus), and ObstacleFree (bypasses obstacles) technologies to take laser cutting to the next level and ensure unmatched precision and detailed results.

Dual Cameras

The CNC machine is equipped with dual 16MP cameras. They capture detailed panoramic views with the assistance of AI algorithms. It helps in analyzing the materials and automatically generates a cutting layout with one click. It reduces material wastage to a great extent.

The close-range camera assists in precise positioning. It minimizes center deviation and makes it less than 0.008 inches. That’s why it is an ideal option even for small objects.

Incredible Safety

xTool MetalFab laser welder has taken safety to the next level with 10 safety features. It is certified with CE, FDA, and FCC. It offers professional-grade protection and ensures incredible performance. Here are its safety features:

1. Emergency Stop Switch
2. USB Safety Key
3. Grip Protection
4. Electrical Safety Design
5. 3-Zone Real-time Temperature Monitoring
6. Lid Closure Protection
7. Drawer Closure Detection
8. Exhaust Fan Detection
9. OD5+ Light Filtering Cover
10. Emergency Stop Switch on CNC

xTool MetalFab Laser Welder and CNC Cutter

Your All-in-One Laser Welder for Metalworking!

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FAQs

Is laser welder any good?

Laser welding is a cost-effective solution that offers precise and quick welding. It is the best choice for high-volume welding jobs. The weld quality is incredible; clean and even from every angle. The upfront cost is high, but the running cost is quite low.

How to choose a laser welding machine?

While choosing a laser welding machine, you need to check the compatible materials, welding modes, heat-affected zone, speed, controls, safety features, etc. We have explained all these factors in detail to make your selection easier.

What thickness can a laser welder weld?

A laser welder can weld material from thin materials to up to 8mm thick or more. It depends on the wattage of the laser machine. MetalFab can weld up to 5mm thick materials in a single pass, which is perfect for general welding purposes.

How much power does a laser welder need?

A laser welder with 800W power can weld materials up to 4mm in thickness. If you go with a 1200W laser welder, it can weld a 5mm thick material in a single pass. It also depends on the welding technology and other factors.

Conclusion

Laser welding is the future, and people are shifting to this innovative technology. It offers incredible precision, speed, and weld quality. While buying a laser welding machine, consider the important factors and features we have discussed. It will help you select the right welding machine for your needs.

xTool MetalFab laser welder and CNC cutter is a compact industrial-grade welding, cutting, and cleaning machine that can help you turn your ideas into reality. It’s an all-in-one laser machine to express your creativity and make metalworking simple.