Automated Laser Welding

Retrofit Laser Welding

The Retrofit Laser Welding Solution upgrades existing MIG/MAG or TIG robotic welding cells into high-performance laser welding systems. It enables welding speeds up to 12 m/min, delivers an exceptionally narrow Heat-Affected Zone (HAZ), and ensures high seam quality with no post-processing. By reusing the existing robot and controller, investment requirements are significantly reduced compared to installing a new system. The Diodela retrofit package offers rapid deployment—typically within 2 days—and seamless integration via Ethernet TCP/IP or Digital I/O. Its high flexibility allows adaptation to diverse product geometries and production needs, providing a cost-effective, low-risk transition from conventional arc welding to advanced laser welding technology.

  • Compatible with leading industrial robot platforms, including:

    FANUC (standard), YASKAWA, KUKA, ABB, and UR (optional)

  • Advanced control systems:

    Integrated vision-based monitoring and weld-seam tracking functionalities provide real-time process feedback and enable dynamic trajectory compensation in response to seam deviations.

  • High-quality welding results:

    Characterized by extremely low thermal input, negligible spatter and distortion, and a weld seam that typically meets final-quality requirements without any post-processing.

  • High precision and speed:

    Scanning velocities up to 10 m/s, positioning accuracy down to ±0.02 mm, and welding speeds reaching 12 m/min for thin-gauge materials

Technical specifications

LASER SOURCE:

Continuous-wave (CW) single-mode fiber laser with an available power range from 1 to 6 kW, configurable according to application requirements.

WELDING DEPTH:

0.5–15 mm (depending on power, material, and joint geometry).

LASER WELDING TORCH:

Two-axis scanning mirror ensures easy programming. Integrated CCD vision module for real-time process monitoring; laser isolator enabling stable welding operation at variable approach angles.

COOLING:

Both the source and the torch are cooled by water, ensuring continuous, uninterrupted 24/7 industrial operation.

SAFETY SYSTEM:

Laser safety control fully integrated into the robotic safety system.

COMMUNICATION INTERFACE (ROBOT CONTROLLER ↔ LASER PLC):

Depending on the robot platform, communication is provided via Ethernet TCP/IP or Digital I/O; additional industrial communication protocols can be supported upon request.

AIR KNIFE (OPTIONAL):

Compressed-air connection to the torch to protect torch components from contaminants such as spatter, fumes, and particulates.

WELD SEAM TRACKING SENSOR (OPTIONAL):

Seam-tracking sensor enabling dynamic trajectory correction in response to seam misalignment and providing post-weld quality verification capabilities.

Retrofit installation process

  • Removal of the existing welding torch

    The currently installed MIG/MAG or TIG torch is dismounted, clearing and preparing the robot’s end-of-arm tooling interface for integration of the laser welding module.

  • Installation of the new laser welding torch

    The Diodela two-axis galvanometric laser welding torch is installed, featuring an integrated CCD camera for real-time process visualization and a laser isolator that enables stable welding at variable approach angles.

  • Integration of the laser source

    The Diodela laser source is interfaced with the robot controller via Ethernet TCP/IP for newer robot platforms or via Digital I/O for legacy systems. Additional industrial communication protocols can be supported if required.

  • Controller synchronization and system calibration

    The laser PLC and the robot controller are configured for fully synchronized operation, including setup of control signals, calibration of optical axes, and adjustment of focusing parameters.

  • Testing and process parameter optimization

    Trial welds are performed to validate system performance, during which optimal laser power, welding speed, and focal parameters are defined based on the customer’s material type, thickness, and joint configuration.

  • Operator training

    A Diodela engineer provides operator training covering laser system operation, routine maintenance procedures, and essential laser safety practices.

  • Start of operation

    Following successful validation and parameter optimization, the system is commissioned for full production operation. The complete retrofit procedure is typically completed within 2 days, ensuring minimal disruption to manufacturing activities.

You Need Custom Solution?

Our laser experts will help you choose the most efficient solution for your business needs, provide comprehensive training, and offer consultation on any question.