What Is Laser Welding? Benefits, Applications, and How It Compares to GMAW/GTAW

What Is Laser Welding?

An Introduction to Modern Welding Technology

Laser welding is a cutting-edge welding technology that uses a concentrated beam of light to fuse materials with extreme precision. Known for high speed, minimal distortion, and strong, clean joints, laser welding is gaining popularity in advanced manufacturing sectors like aerospace, automotive, and medical device fabrication.

In this guide, we’ll answer the most common questions people ask about laser welding—covering everything from how laser welding works to how it compares to gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW). Whether you’re a fabricator considering new tools or a curious hobbyist, this overview will help you determine if this high-precision method fits your needs.

How Does Laser Welding Work?

Laser welding relies on a focused beam—delivered via fiber optics or mirrors—to melt material at the joint. The result is a narrow, deep weld with a small heat-affected zone and minimal thermal distortion.

Shielding gas, typically argon or helium, is used to prevent oxidation. The process can be automated through CNC or robotic systems, making it ideal for high-precision or high-volume applications. It's commonly used on metals like stainless steel, aluminum, titanium, and even dissimilar metals.

 Learn more about equipment standards and safety in AWS Standards and Publications.

Is Laser Welding as Strong as GMAW?

Yes—laser welding can be just as strong as GMAW, especially on thin or medium-thickness materials. In many cases, it produces cleaner welds with less spatter and distortion than MIG, making it preferable in precision fabrication.

While MIG is more forgiving on joint fit-up, laser welding offers better control, especially in automated environments.

Is Laser Welding as Strong as GTAW?

Laser welding and GTAW welding both offer high-quality, precise welds—but laser welding is significantly faster and easier to automate. TIG requires a skilled operator and more manual control, while laser welding reduces the need for human input once the system is set up.

In industries where repeatability and speed matter—like medical device manufacturing or electronics—laser welding technology often has the edge.

For training on both GTAW and laser techniques, explore AWS Certification and Education.

Is Laser Welding as Strong as Arc Welding?

Laser welds can be just as strong as arc welds, especially on materials up to half an inch thick. However, arc welding is generally more flexible for larger or less precise jobs, while laser welding thrives in high-precision, low-distortion applications.

If your project involves tight tolerances and clean welds, laser welding is a superior option.

Does Laser Welding Actually Work?

Absolutely. Laser welding is a proven process used in mission-critical industries where precision and strength are non-negotiable. It's not experimental—it’s a mainstream option in automotive production, aerospace fabrication, and cleanroom environments.

Its ability to consistently deliver strong, clean, low-distortion welds has made it a go-to method in high-end manufacturing.

How Thick of Metal Can a Laser Welder Weld?

Most industrial laser welding systems can handle materials up to 0.5 inches (12 mm) thick in a single pass, depending on the power of the laser and the type of material. Multi-pass techniques can extend that capability, but for extremely thick materials, traditional arc or GMAW welding may still be more efficient.

What Are the Disadvantages of Laser Welding?

While powerful and precise, laser welding has limitations:

• High equipment cost: Laser systems are expensive to acquire and maintain.
• Tight fit-up required: Joints must be accurately aligned for quality results.
• Not ideal for thick sections: Without multiple passes, it’s best for thinner materials.
• Specialized safety needs: High-power lasers pose serious risks without proper precautions.

Despite these challenges, many industries find that the benefits outweigh the drawbacks—especially when speed, repeatability, and quality are top priorities.

What Is the Greatest Hazard to a Welder While Laser Welding?

The biggest danger is exposure to laser radiation, which can cause permanent eye or skin damage. Proper laser-rated enclosures, interlocks, signage, and laser-specific PPE are essential for safety.

Always follow the guidelines found in AWS Standards and Publications.

Do You Need a Welding Helmet for Laser Welding?

Yes—but not just any helmet. Laser welding requires laser-rated protective eyewear that matches the specific wavelength of the laser. Standard welding helmets do not provide adequate protection.

Always use PPE and safety systems rated for your equipment and wavelength, and consult the manufacturer's safety guidelines before operation.

How Much Does a Laser Welder Make a Year?

In the U.S., laser welders typically earn between $50,000 and $80,000 annually, depending on industry, experience, and certifications. Welders in cleanroom or high-tech environments may command even higher salaries due to the specialized nature of their work.

Want to boost your earning potential? Get certified through AWS Certification and Education and access exclusive training through AWS Membership.

Common Applications of Laser Welding

Laser welding is commonly used in sectors where high-speed, low-distortion, and repeatable results are critical:

• Automotive: Body panels, EV battery packs, and structural parts.
• Medical Devices: Small-scale welds on titanium and stainless steel.
• Aerospace: Lightweight, precision-critical components.
• Electronics: Heat-sensitive assemblies with fine tolerances.

These industries rely on laser welding to meet high standards of accuracy and cleanliness—often under strict regulatory conditions.

Learn more about laser welding applications from Xometry and Laserax.

Final Thoughts: Is Laser Welding Right for You?

If your operation values speed, precision, and automation, laser welding technology may be a worthwhile investment. It’s especially useful in:

• High-precision manufacturing
• Robotics and automation workflows
• Applications requiring aesthetically clean or repeatable welds

As the demand for smarter fabrication grows, so does the relevance of laser welding. Want to explore your next steps? Visit AWS Certification and Education and consider joining AWS Membership for access to training, resources, and a community of experts.