Choosing a laser welding machine should not be reduced to the simple rule: the higher the power, the better. The power of the laser source affects the penetration depth, welding speed and the range of material thicknesses that can be processed, but the material, the type of joint, the gap between the components, surface preparation and production organisation are equally important. A machine selected solely ‘to allow for future needs’ may result in a higher capital outlay without a commensurate benefit in day-to-day operations.
Choosing a laser welder should not be reduced to the simple rule: the higher the power, the better. The power of the laser source affects the penetration depth, welding speed and the range of material thicknesses that can be processed, but the material, the type of joint, the gap between the components, surface preparation and production organisation are equally important. A machine selected solely ‘to allow for future needs’ may result in a higher investment cost without a commensurate benefit in day-to-day operations.
The best laser welder is one whose power output matches the workpieces produced most frequently, rather than just the thickest component that appears only occasionally. A workshop producing stainless steel balustrades requires a different solution to a manufacturer of enclosures and lightweight structures, and yet another to a facility welding machine components or parts with larger cross-sections.
What determines the choice of power for a laser welder?
The power of a laser welder determines how much energy can be delivered to the material within a given time. Higher power enables faster welding, a deeper penetration, and the ability to work with thicker material. However, this does not mean that every weld should be carried out at maximum settings.
With thin sheet metal, excessive power can increase the risk of distortion, burn-through or an excessively large heat-affected zone. Conversely, with thick workpieces, a power source that is too weak will limit the welding speed and may fail to provide the required penetration. Therefore, when making a selection, one should analyse not only the thickness but also the type of metal, the length of the welds, the number of workpieces and the required production rate.
The type of joint is also significant. Butt, fillet, corner and lap welds may require different settings. The welding position, access to the workpiece and the possible use of filler wire also have an impact. In practice, the outcome is determined by the entire process, not just the power output of the laser.
Approximate material thicknesses for 1000–3000 W laser welders
The ranges below apply to CORMAK handheld laser welders and should be treated as a starting point for selecting a machine. The actual result depends, amongst other things, on edge preparation, material quality, the joint gap, head parameters, welding speed and the shielding gas used.
| Material | 1000 W | 1,500 W | 2000 W | 3000 W |
|---|---|---|---|---|
| Stainless steel | 0.5–3 mm | 0.5–4 mm | 0.5–5 mm | 0.5–8 mm |
| Mild steel | 0.5–2.5 mm | 0.5–3.5 mm | 0.5–4.5 mm | 0.5–8 mm |
| Galvanised steel | 0.5–1.2 mm | 1.5–1.8 mm | 1.5–4 mm | 1.5–7 mm |
| Aluminium | 0.5–1.2 mm | 1.5–1.8 mm | 1.5–4 mm | 1.5–7 mm |
| Brass | 0.5–1.2 mm | 1.5–1.8 mm | 1.5–2.5 mm | 1.5–4 mm |
1000 W laser welder – for thin workpieces
The 1000 W model is well suited to workshops that work mainly with thin materials. It is a sensible choice for the production of metal furniture, balustrades, lightweight structures, enclosures, decorative items and stainless steel components.
This machine is suitable when most joints involve sheet metal and profiles with a thickness of around 0.5–2 mm. It ensures high precision and helps to minimise distortion of thin components. However, it requires good preparation of the joint and the correct selection of speed, as it has less margin for error with thicker sections.
Opting for the 1000 W model makes sense when thicker workpieces are rare and the priority is cost-effective work with thin material. It will not, however, be the best solution for a company that regularly welds 3–4 mm steel.
1500 W laser welder – a versatile choice for many workshops
The 1500 W model is often chosen by businesses that handle a variety of jobs. It allows for efficient work with thin steel, whilst also providing greater capacity for regular welding of components approximately 3 mm thick.
This model is ideal for metalworking workshops, for the production of gates, fences, enclosures, tables, lightweight structures and stainless steel components. It is a good choice when a company wishes to replace some MIG/MAG or TIG welding in repeat production runs.
Compared to the 1000 W variant, the 1500 W model offers greater flexibility. However, this does not mean it will always be the better option. If a company works exclusively with thin components, the full potential of the higher-powered unit may not be utilised.
2000 W laser welder – for greater productivity
A 2000 W laser welder is the right choice for companies that regularly work with stainless steel, carbon steel or thicker aluminium. The higher power allows for faster welding, increased penetration depth and a reduction in the number of passes required for more challenging workpieces.
A machine of this class is ideal for the production of frames, machine parts, structures, industrial enclosures, tanks and components with larger cross-sections. It is also a good choice when a workshop wishes to increase the throughput of a workstation without compromising on quality control.
The 2000 W model makes sense where material 3–4 mm thick is used regularly, rather than just occasionally. It is also worth considering when the number of metres of welds produced is high and reducing cycle time is a priority. The specifications of the CORMAK WL2000 model include, amongst other features, an automatic wire feeder and water cooling.
3000 W laser welder – for thicker materials and high-volume production
The 3000 W power rating is designed for intensive production and working with thicker materials. This variant offers the highest power reserve of the machines discussed here and allows for more efficient joining of thicker components made of stainless steel, carbon steel, aluminium and galvanised steel.
This is the solution for manufacturers of heavier structures, machinery, industrial components and parts requiring high productivity. The CORMAK WL3000 machines feature continuous and modulated operating modes, an automatic wire feeder and water cooling, which makes it easier to adapt the process to the type of joint.
However, the 3000 W model is not the automatic choice for every workshop. If daily production mainly involves thin sections and sheet metal, a 1500 W or 2000 W machine may be more cost-effective.
The material and preparation of the joint are just as important as the power
Stainless steel and carbon steel usually allow for a stable process when the parameters are correctly selected. Aluminium and brass require greater control, as they react differently to the applied heat and are more sensitive to improper surface preparation.
Before welding, rust, paint, oil, scale and other contaminants must be removed. The components should be precisely fitted. Too large a gap may require the use of filler wire and a change in parameters. In practice, the quality of the workpiece preparation often determines the result more than a difference of a few hundred watts in power.
The shielding gas, wire diameter, head feed speed, swath width and focal point setting are also important. Technical trials on actual workpieces are the best way to validate the parameters before commencing mass production.
What power rating should you choose for a laser welder?
A 1,000 W welder will be suitable for thin components and light-duty production. The 1500 W model will serve as a versatile machine for many workshops. The 2000 W variant is worth choosing for regular work with materials around 3–4 mm thick and where higher throughput is required.
A 3000 W laser welder will be a good choice for companies working with thicker materials, requiring deeper penetration and high throughput. Before purchasing, it is worth drawing up a simple list: types of metal, typical thicknesses, the most common joints and the planned number of operating hours.
Summary
The choice of laser welder power should be based on the actual tasks carried out by the company. The highest power output is not always the best choice, particularly if most of the production involves thin sheet metal, profiles and decorative elements.
Such an analysis allows you to select a power rating that will neither restrict the workstation nor represent an unnecessary investment cost. A well-chosen laser welder speeds up work, improves repeatability and provides the company with real scope for future growth.
