Owning a Laser Welding Machine:
25 Questions, Answered
Before a laser welding system is signed off, five departments ask five different sets of questions. Maintenance wants to know what happens when it breaks. Production wants to know how fast a mold gets back on the press. Quality wants to know whether two operators produce the same weld. Process engineering wants to know who can actually run it. Management wants to know at what point it beats outsourcing. These are Sigma Laser’s own answers — the same ones our engineers give on the phone.
Maintenance & Technical Support
What happens when something goes wrong — and how long you wait.
Sigma Laser laser welding machines support remote diagnosis via an integrated USB interface. The machine is connected via USB to the customer’s PC, which then establishes an internet connection to Sigma Laser. Our technicians can analyze the machine remotely and identify many technical issues without requiring an immediate on-site service visit.
In addition, photos and videos provided by the customer are often very helpful for diagnosing mechanical issues, unusual machine behavior, or visible error conditions. This combination allows many problems to be identified quickly and significantly reduces unnecessary service visits and downtime.
Our priority is to react quickly and minimize production downtime. If Sigma Laser is contacted before 2:00 p.m., we can typically perform the initial remote diagnosis on the same day.
Based on the diagnosis, the necessary corrective measures are initiated no later than the following working day. Depending on the cause, many issues can be resolved remotely or by replacing individual components. If an on-site service visit is required, it can be organized based on the diagnosis without losing additional time on preliminary troubleshooting.
Yes. Sigma Laser laser welding systems are designed so that most hardware issues can be resolved by replacing individual components or modules directly at the customer’s site.
Based on the initial diagnosis, the affected component can usually be identified and the appropriate replacement or repair can be arranged. Returning the complete laser welding machine to Sigma Laser is only necessary in rare cases. This modular service approach significantly reduces transportation effort and machine downtime.
No. In general, there is no need for customers to keep expensive spare parts in stock. The machine components are designed for long-term operation, and in the event of a technical failure, the required part can be identified through diagnosis and the appropriate service measures can then be initiated.
There are, however, a small number of consumable and wear parts for which keeping a limited stock on site is practical. These parts are inexpensive and their replacement is part of normal laser welding machine operation and maintenance.
Regular preventive maintenance helps identify wear, contamination, and potential technical issues before they lead to an unexpected machine failure.
Sigma Laser recommends preventive maintenance every 1,000 operating hours or at least every two years, whichever comes first. During maintenance, relevant machine components and functions are inspected and serviced as required. This helps maintain reliable laser welding machine operation and reduces the risk of unplanned downtime.
Production & Manufacturing
What the machine changes on the shop floor.
Laser welding itself can usually be performed relatively quickly and with very localized heat input. However, the welding process is normally not the final step of the repair.
After laser welding, the repaired area typically requires mechanical finishing, such as grinding, milling, polishing, or other machining operations, depending on the component and the required surface quality. The total time until the tool or mold can return to production therefore depends mainly on the extent of the repair and the necessary finishing work.
Yes. One of the major advantages of laser welding is the very low and highly localized heat input. Compared with conventional welding processes, this results in minimal to virtually no thermal distortion of the component.
This makes precision laser welding particularly suitable for precision components, molds, and tools where dimensional accuracy and preservation of the original geometry are critical. After welding, only the repaired area normally requires the necessary mechanical finishing.
Laser welding is particularly suitable for heat-sensitive components because the energy can be applied very precisely and locally. This keeps the heat-affected zone small and minimizes the risk of distortion or thermal damage.
In addition, suitable welding parameters and technologies such as Sigma Laser’s SPT (Super Pulse Technology) can further optimize the energy input and the welding process. By precisely controlling the laser pulse, even demanding and heat-sensitive components can be repaired with very low thermal impact.
In many cases, yes. Laser welding requires a clear line of sight between the welding optics and the repair area, but flexible positioning of the welding head provides considerable freedom when accessing difficult locations.
Sigma Laser laser welding systems can be equipped with tilting and swiveling optics, allowing the laser beam to be directed into areas that would otherwise be difficult to reach. Combined with the machine’s positioning and movement capabilities, this can often avoid or significantly reduce the need to disassemble or reposition complex components.
The choice of the right laser welding machine depends largely on the size and weight of the component. For smaller components and inserts weighing up to approximately 300 kg, a stationary laser welding machine is usually the most practical solution.
For large and heavy components, particularly parts weighing significantly more than 400 kg, it is generally more efficient to bring the laser welding machine to the component rather than moving the component to the machine. In these cases, mobile laser welding systems, such as the Sigma Laser Sirius or Sineo, are the preferred solution.
This combination of stationary and mobile laser welding machines allows users to cover a very wide range of mold, tool, and industrial repair applications.
Yes. A laser welding machine can generally be integrated into an existing industrial workshop without major infrastructure modifications. The systems are designed for practical daily use in normal manufacturing and toolmaking environments.
Appropriate laser safety measures must, however, be implemented. Depending on the installation and application, the working area can for example be secured using certified laser safety curtains. This makes it possible to create a suitable laser-safe working area within an existing workshop without requiring major structural modifications.
This is particularly advantageous for mobile laser welding machines, which can be moved directly to large molds, tools, or components while the required laser-safe working area is established around the application.
Having an in-house laser welding machine gives manufacturers direct control over when and how repairs are carried out. Damaged molds, tools, and components no longer have to be transported to an external laser welding service provider and scheduled according to the supplier’s availability.
Repairs can be prioritized according to the company’s own production requirements and, in urgent cases, started immediately. This eliminates transportation and external waiting times and can significantly shorten the overall repair cycle.
In addition, considerable internal handling is eliminated: parts do not have to be packed and shipped, repair requirements do not have to be explained to an external supplier, and the company retains direct control over the repair itself.
Especially where laser welding repairs are required regularly, an in-house laser welding system provides greater flexibility and makes production planning less dependent on external service providers.
Quality Management
Whether the result is repeatable — and who makes it so.
Manual laser welding remains a skilled process, and the experience and technique of the operator have a significant influence on the final welding quality. For this reason, proper operator training is essential. Sigma Laser provides practical training to ensure that operators understand both the laser welding machine and the welding process itself.
At the same time, virtually all relevant welding parameters can be stored in the laser welding system and recalled for recurring applications. Once suitable parameters have been established for a specific material and repair task, they can therefore be reused by different operators.
The combination of well-trained operators and reproducible stored welding parameters is the key to achieving consistently high laser welding quality.
Operator experience plays an important role in manual laser welding. Even with precisely defined and stored welding parameters, the operator controls the movement of the laser beam, the positioning of the filler wire, and the interaction with the workpiece. Good results therefore depend not only on the laser welding machine, but also on the operator’s practical skills.
However, laser welding can be learned systematically. Sigma Laser provides a three-day practical operator training course, combining machine operation, hands-on welding of real components, and laser safety. This gives new operators a solid foundation for achieving professional and repeatable welding results, while their skill naturally continues to improve with practical experience.
High-quality laser welding provides the foundation for the final cosmetic and functional quality of a repaired component. Correct welding technique is important: unsuitable parameters or improper manual welding can negatively affect the repair and make subsequent finishing more difficult.
After laser welding, the repaired area is normally finished using processes such as grinding, milling, polishing, or other machining operations, depending on the required geometry and surface quality.
With a properly executed laser welding repair followed by the appropriate finishing process, the repaired area can be restored to the required dimensional, functional, and cosmetic standard.
Yes. A single laser welding machine can be used for a wide range of materials, including tool steels, stainless steels, titanium, and many specialty alloys. An important factor is selecting the appropriate filler material for the base material and the specific repair application.
More challenging are materials with a high carbon content. At carbon levels above approximately 1.2%, the risk of cracking during laser welding can increase significantly.
For these demanding materials, Sigma Laser’s SPT (Super Pulse Technology) can be particularly effective. By precisely controlling the energy input and pulse characteristics, SPT can significantly reduce the tendency to crack and extend the range of materials that can be successfully processed with a laser welding machine.
Sigma Laser laser welding machines are equipped with a 10-inch touchscreen display that provides central access to machine operation and welding parameters. Virtually all relevant welding parameters can be set, stored, and recalled directly via the touchscreen.
Once suitable parameters have been established for a specific material, component, or laser welding repair, they can be saved and reused for similar applications. This significantly reduces setup time and provides operators with a reliable starting point for repeatable welding results.
However, stored parameters do not replace operator skill. Manual laser welding still requires proper training and practical experience.
Process Engineering & Daily Operation
Who can run it, and what happens on a busy week.
Sigma Laser provides a three-day practical training program for new operators of our laser welding machines.
The first day focuses on becoming familiar with the laser welding machine, its functions, controls, and welding parameters. On the second day, operators work on real components and typical laser welding repair applications. The third day combines further practical welding and repetition with comprehensive laser safety training.
Based on our experience, we recommend training three operators whenever possible. Manual laser welding requires not only technical understanding and manual skills, but also patience, concentration, and the ability to work calmly and precisely for extended periods. Not every employee is equally suited to this type of work.
In a typical group of three trainees, we often find that one develops into a very good laser welding operator, one reaches a solid working level, while another is better suited to simpler welding tasks. Training several operators therefore provides operational backup and increases the likelihood of developing at least one highly skilled laser welding specialist.
Sigma Laser laser welding machines are designed around a simple principle: the operator should not need to be an IT specialist to use the machine effectively.
Over more than 20 years, we have listened closely to laser welding operators and continuously incorporated their practical experience into the operating concept of our machines. The user interface of the 10-inch touchscreen was developed together with experienced screen designers to make daily operation as clear, intuitive, and practical as possible.
Virtually all relevant laser welding parameters can be adjusted directly via the touchscreen. Once suitable settings have been established for a particular material or laser welding repair application, they can be stored and recalled for future jobs.
This allows operators to switch quickly between different repair tasks without complex programming. The operating concept is the result of many years of practical experience and was also one of the important design elements recognized with a German Design Award.
A good laser welding machine should not require the operator to be an IT specialist. This principle has been central to the development of Sigma Laser systems.
For more than 20 years, we have listened closely to laser welding operators and continuously incorporated their practical experience into the operation and design of our machines. The user interface of the 10-inch touchscreen was developed together with experienced screen designers, with a strong focus on making machine operation clear, intuitive, and easy to understand.
This operating philosophy also helps operators deal with machine issues in daily use. If further technical analysis is required, Sigma Laser can support the customer through remote diagnosis via the machine’s integrated USB interface, supplemented by photos or videos when helpful.
The quality of this overall design and operating concept has also received external recognition through a German Design Award.
With very large and heavy components, the safest and most practical approach is often not to move the component at all. Instead, the mobile laser welding machine is brought directly to the workpiece.
For smaller components and inserts up to approximately 300 kg, a stationary laser welding machine is generally practical. For substantially heavier components, particularly those above 400 kg, mobile laser welding systems such as the Sigma Laser Sirius or Sineo can eliminate the need for unnecessary lifting, transportation, and repeated repositioning of the workpiece.
The mobile laser welding machine is positioned around the component, and the welding head is brought to the repair location. Its large movement range and flexible positioning make it possible to reach different areas of large molds, tools, and industrial components while the workpiece remains securely in place.
This is one of the major advantages of mobile laser welding for large mold and tool repair.
Every laser welding machine naturally has a finite processing capacity, particularly in manual laser welding. However, Sigma Laser systems are designed for 24/7 industrial operation, allowing customers to increase utilization significantly when repair demand temporarily rises.
If necessary, additional shifts can be introduced and the laser welding machine can be operated continuously. This gives manufacturers considerable flexibility to respond to temporary peaks in laser welding repair demand without immediately requiring additional equipment.
The actual capacity ultimately depends on the type and complexity of the welding applications and the availability of trained operators.
Management & Investment
When the numbers turn in your favour.
Based on our experience, companies spending approximately €600 or more per month on external laser welding services should already consider whether investing in their own laser welding machine is economically more attractive.
The external welding invoice is only part of the real cost of outsourcing. Components have to be organized, packed, shipped or transported, and someone within the company has to communicate exactly what needs to be repaired. There are also waiting times, internal coordination, and the risk that the external service provider does not perform the repair exactly as intended.
With an in-house laser welding machine, much of this additional handling disappears. Repairs can be carried out when they are needed, the responsible employees retain direct control over the work, and transportation and external scheduling are eliminated.
For this reason, the economic case for an in-house laser welding system can start at a surprisingly low level of regular external welding expenditure. The exact break-even point naturally depends on the individual company, its repair volume, labor costs, and the value of the time saved.
The time saving from in-house laser welding is often much greater than the actual welding time itself.
When a component is sent to an external laser welding service provider, the complete process includes preparing and packing the part, organizing transportation, communicating the repair requirements, waiting for the supplier’s available capacity, performing the repair, and transporting the component back. Only then can any necessary machining or finishing continue.
With an in-house laser welding machine, most of these steps disappear. The component can often move directly from production to the laser welding repair and then to the required finishing process. In urgent cases, the repair can be prioritized immediately according to the company’s own production requirements.
The comparison is therefore not simply external welding time versus internal welding time. The real advantage comes from eliminating transportation, waiting, scheduling, and coordination time – which can significantly shorten the complete repair cycle and reduce production downtime.
A laser welding machine should not be considered a solution for only one specific repair task. Its greatest value comes from using it across a wide range of applications within the company – from mold and tool repair to precision components, different materials, and both planned and urgent repair work.
Good operator training is particularly important. When several employees are trained to use the laser welding system, the machine is not dependent on the availability of a single specialist and can also be operated in additional shifts when required.
Stored welding parameters make recurring applications faster to set up, while regular preventive maintenance helps maintain high machine availability over many years.
The combination of versatile applications, trained operators, reusable welding parameters, and preventive maintenance is the key to maximizing the long-term utilization and return on investment of a laser welding machine.
Still have a question we have not answered?
Every answer below links to a full article with the practical detail.
Talk to our engineers — our engineers answer these questions every week, for machines in the field and for systems that are still being evaluated.
Write to us at info (at) sigma-laser.com and describe the components you repair; we will tell you which system fits and what it would change in your process.
Phone: +49 (0)6181 413 6679