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WMG

Laser Beam Welding Facilities and Equipment

Facilities and Equipment

At WMG, our cutting-edge laser welding facilities support industry and research partners in developing next-generation joining solutions. Our research team has access to a flexible and modular pool of laser systems, integrated with novel welding heads, beam shaping technologies, and state-of-the-art sensors for in-process quality monitoring. This enables precise control over welding processes, ensuring high-quality and repeatable results. To further enhance design optimisation and validation, we leverage advanced multi-physical simulation suites, allowing for early-stage testing and refinement.

Our expertise spans three key areas:

  • Robotics Laser Beam Welding – High-precision, automated welding solutions for complex geometries and large-scale applications.
  • 4-Axis CNC Laser Beam Welding – Versatile and highly controlled welding for intricate and high-accuracy requirements.
  • Laser Welding with Dynamic Beam Shaping – Adaptive beam control to enhance weld quality, reduce defects, and improve efficiency across diverse materials and thicknesses.

Our key capabilities

Our laser welding research is underpinned by a suite of advanced capabilities, enabling a deep understanding of laser-material interactions and the development of industry-ready solutions:

  • Fundamentals of Laser-to-Material Interaction – Investigating how different materials respond to laser energy to optimise weld quality, minimise defects, and enhance performance.
  • Advanced Process Modelling and Digital Twins – Using predictive simulations and digital twin technology to refine welding parameters, reduce trial-and-error, and accelerate process development.
  • In-Process Monitoring and Control – Leveraging real-time sensors and AI-driven analysis to detect and correct welding defects as they occur, ensuring precision and consistency.
  • Full-Scale Prototype and Production-Ready Validation – Scaling up from research to industrial application, validating laser welding processes for real-world manufacturing environments.
  • Advanced Testing and Characterisation – Conducting in-depth analysis of weld properties, including mechanical strength, microstructure, and durability, to ensure high-performance outcomes.

Equipment

Laser systems: LASERLINE LDF 6000; COHERENT ARM FL10000; TRUMPF Brightline 6000; Manual handheld laser (1.5kW with wire feeder); CIVAN 14 kW with dynamic beam shaping

Welding heads: Precitec Weldmaster (1D wobbling head with motorised collimator); K-lab 200 (2D scanner/manual collimator). Scansonic ALO4-0 (2D wobbling with seam tracking and spot-in-spot module); Scansonic RLW-S (2D scanner/auto collimator); TRUMPF PFO (2D scanner/auto collimator); SmartMOVE (2D scanner)

In-process sensors: high speed camera; IR camera; photodiodes; OCT​, XARION ultrafast optical microphone

Diagnostic kits: PRIMES power and focus meter​

Simulation suites: Flow3D; Comsol Multiphysics

Dynamic Beam Shaping

Dynamic Beam Shaping is revolutionising laser welding by enabling precise, real-time control over beam characteristics to enhance weld quality and process efficiency. By tailoring the laser beam's properties to specific materials and applications, we can optimise energy distribution, minimise defects, and improve joint integrity. Our expertise in design and dynamic control of beam shapes includes:

  • Shape Geometry – Customising beam profiles to achieve optimal heat distribution and penetration.
  • Shape Sequencing – Modulating beam shape throughout the welding process to control material behaviour and reduce defects.
  • Beam Motion – Dynamically adjusting beam patterns to improve stability and accommodate complex geometries.
  • Focus Steering – Precisely shifting the beam focus to maintain consistency and adapt to varying material thicknesses.

This advanced capability allows us to push the boundaries of laser welding, delivering stronger, more precise, and more efficient welded structures across multiple industries.