Laser Welding
Delivering cutting-edge solutions to customers worldwide.
Laser Welding
Delivering cutting-edge solutions to customers worldwide.
Introduction
Laser welding with Max Photonics hand held fibre laser welding equipment
Wilkinson Star Limited are proud to be the exclusive partners for Max Photonics hand held laser welding equipment in the UK & Ireland.
Targeted at sheet metal fabrication industries, this technology has now been adopted into a growing list of applications including nuclear, aerospace, pharmaceutical and catering to name but a few.
Max Photonics fibre laser technology is a great supplement to conventional welding methods in most fabrication workshops. This technology can offer many advantages over conventional welding methods.
Advantages Over Conventional Welding
• Fast welding speeds
• Minimal heat affected zone
• Minimal material distortion
• High precision and neat welding seams
• Up to 4 times faster than TIG
• Low consumable usage
• High repeatability
• Minimal training required
• Uniform weld bead
• Ability to weld various materials as well as dissimilar materials
• Improves production efficiency
• Reduced post weld cleaning times
• Easy to use
• Low application costs
• Efficient energy usage
• High welding strength
• Excellent welding performance
LIGHTER
SMALLER
PORTABLE
HIGH PERFORMANCE
Laser welding with Max Photonics hand held fibre laser welding equipment
Wilkinson Star Limited are proud to be the exclusive partners for Max Photonics hand held laser welding equipment in the UK & Ireland.
Targeted at sheet metal fabrication industries, this technology has now been adopted into a growing list of applications including nuclear, aerospace, pharmaceutical and catering to name but a few.
Max Photonics fibre laser technology is a great supplement to conventional welding methods in most fabrication workshops. This technology can offer many advantages over conventional welding methods.
Advantages Over Conventional Welding
• Fast welding speeds
• Minimal heat affected zone
• Minimal material distortion
• High precision and neat welding seams
• Up to 4 times faster than TIG
• Low consumable usage
• High repeatability
• Minimal training required
• Uniform weld bead
• Ability to weld various materials as well as dissimilar materials
• Improves production efficiency
• Reduced post weld cleaning times
• Easy to use
• Low application costs
• Efficient energy usage
• High welding strength
• Excellent welding performance
LIGHTER
SMALLER
PORTABLE
HIGH PERFORMANCE
Safety
Hand held fibre laser welding safety guidance
Lasers are classified into several classes depending on the level of hazard
they present and their ability to cause damage to the operator and others
within the surrounding area, with the highest Class 4 representing the most
dangerous lasers available. EN-60825-1 outlines the classification and safety
guidance of laser products.
Handheld fibre laser welding machines are classified as hazardous, Class
4 laser products, but with the required PPE to protect the operator and
a purpose built Kyrus Automation Class 4 laser welding enclosure, this
technology is safe to use. Users can enjoy the many benefits that handheld
fibre laser welding offers over traditional welding methods.
The difference between laser welding and traditional arc welding processes
is that laser energy is used instead of an electric arc to form the weld pool.
As such, additional/process specific safety measures must be considered
when operating this equipment.
It is mandatory that any company using Class 4 laser appliances, has a suitably
qualified Laser Safety Officer who is responsible for laser safety onsite.
NEW Dedicated Laser Welding Helmet with ADF
• A Weltek Kapio-based helmet
• With a new specific laser Z4 ADF, certified to EN 207
• With Airkos PAPR solution available
Laser Radiation
Exposure to laser light can inflict severe retina and/or cornea injuries
leading to permanent eye damage and may cause skin damage.
Some laser light is invisible. Safety protocols must be followed to
prevent accidental exposure to invisible, direct and reflected beams.
The system must only be operated in a Laser Controlled Area.
Personal Protection
Appropriately certified eyewear must be worn which is suitable for the laser output wavelength, by both
the operator and anyone within the enclosed working environment. The standards for such protection
are governed by EN-207:2017.
The key aspects of the laser glasses are the optical density rating (OD) and the LB rating. These ratings
determine the level of protection provided from the laser radiated at defined wavelengths. For the
wavelength of 1080nm from Max Photonics fibre laser welding systems, the minimum optical density rating
required for adequate protection is 7 (OD7). The minimum LB rating is 6. All Max Photonics handheld fibre
laser welding systems from Wilkinson Star Limited come supplied with CE marked laser safety glasses with a
rating of OD7+ and LB7, and are tested in accordance with EN-207:2017.
Only the combination of specified laser safety glasses and welding helmet with appropriate filters and face
shield will provide sufficient protection to all personnel present during laser welding. A UV rated helmet
with a shade 4 or 5 lens should be used to protect against the secondary thermal radiation from the plasma
arc that is created during welding. The face shield of the welding mask should be certified to EN-208.
Exposure to infrared (IR) and UV light radiation can cause serious injury to the skin. Operators and all
personnel working within the Laser Controlled Area must wear protective clothing including laser-resistant
and heat resistant gloves, caps, leather apron and other laser-resistant and heat-resistant clothing.
Fume Hazards
As with all welding processes, there is a fume hazard present. The appropriate
measures should be taken to ensure safety, with the most effective method
being an extraction hood coupled with a personal air powered respirator
system for the operator. It is important that any filtration is matched to the
welding process/material.
Wilkinson Star Limited offer an extensive range of extraction and PPE
under the F-Tech and Weltek brands. Further information is available at
www.wilkinsonstar247.com.
Safety
Hand held fibre laser welding safety guidance
Lasers are classified into several classes depending on the level of hazard
they present and their ability to cause damage to the operator and others
within the surrounding area, with the highest Class 4 representing the most
dangerous lasers available. EN-60825-1 outlines the classification and safety
guidance of laser products.
Handheld fibre laser welding machines are classified as hazardous, Class
4 laser products, but with the required PPE to protect the operator and
a purpose built Kyrus Automation Class 4 laser welding enclosure, this
technology is safe to use. Users can enjoy the many benefits that handheld
fibre laser welding offers over traditional welding methods.
The difference between laser welding and traditional arc welding processes
is that laser energy is used instead of an electric arc to form the weld pool.
As such, additional/process specific safety measures must be considered
when operating this equipment.
It is mandatory that any company using Class 4 laser appliances, has a suitably
qualified Laser Safety Officer who is responsible for laser safety onsite.
NEW Dedicated Laser Welding Helmet with ADF
• A Weltek Kapio-based helmet
• With a new specific laser Z4 ADF, certified to EN 207
• With Airkos PAPR solution available
Laser Radiation
Exposure to laser light can inflict severe retina and/or cornea injuries
leading to permanent eye damage and may cause skin damage.
Some laser light is invisible. Safety protocols must be followed to
prevent accidental exposure to invisible, direct and reflected beams.
The system must only be operated in a Laser Controlled Area.
Personal Protection
Appropriately certified eyewear must be worn which is suitable for the laser output wavelength, by both
the operator and anyone within the enclosed working environment. The standards for such protection
are governed by EN-207:2017.
The key aspects of the laser glasses are the optical density rating (OD) and the LB rating. These ratings
determine the level of protection provided from the laser radiated at defined wavelengths. For the
wavelength of 1080nm from Max Photonics fibre laser welding systems, the minimum optical density rating
required for adequate protection is 7 (OD7). The minimum LB rating is 6. All Max Photonics handheld fibre
laser welding systems from Wilkinson Star Limited come supplied with CE marked laser safety glasses with a
rating of OD7+ and LB7, and are tested in accordance with EN-207:2017.
Only the combination of specified laser safety glasses and welding helmet with appropriate filters and face
shield will provide sufficient protection to all personnel present during laser welding. A UV rated helmet
with a shade 4 or 5 lens should be used to protect against the secondary thermal radiation from the plasma
arc that is created during welding. The face shield of the welding mask should be certified to EN-208.
Exposure to infrared (IR) and UV light radiation can cause serious injury to the skin. Operators and all
personnel working within the Laser Controlled Area must wear protective clothing including laser-resistant
and heat resistant gloves, caps, leather apron and other laser-resistant and heat-resistant clothing.
Fume Hazards
As with all welding processes, there is a fume hazard present. The appropriate
measures should be taken to ensure safety, with the most effective method
being an extraction hood coupled with a personal air powered respirator
system for the operator. It is important that any filtration is matched to the
welding process/material.
Wilkinson Star Limited offer an extensive range of extraction and PPE
under the F-Tech and Weltek brands. Further information is available at
www.wilkinsonstar247.com.
Application Materials
Stainless Steel
3mm Fillet Weld
3mm Butt Weld
Aluminium
3mm Fillet Weld
3mm Butt Weld
Carbon Steel
3mm Fillet Weld
3mm Butt Weld
Galvanised
Copper
Brass
Application Materials
Stainless Steel
3mm Fillet Weld
3mm Butt Weld
Aluminium
3mm Fillet Weld
3mm Butt Weld
Carbon Steel
3mm Fillet Weld
3mm Butt Weld
Galvanised
Copper
Brass
Interface
SIMPLE AND EASY TO USE
Key Features
• Embedded with 32 pre-set modes for various materials
• Ability to store up to 32 user defined programs
• Minimal training time needed for beginners to operate
the welding system
• Synergic interface allows the user to select the material,
plate thickness and joint configuration for quick set up
• Advanced user menu for user defined set up for
advanced operators
• Detailed warning page for easy diagnosis
• Full control over external wire feed system
• Password protected advanced service menu
• Fish scale welding mode
• Easily switch between CW, pulse and shooting modes
7 INCH TOUCH SCREEN
MA1-35
800W Power
Key Features
• Portable design
• Compact handheld welding torch
• Stable performance and reliable quality
• Six layers of safety protection
• Simple operating system
• Easy installation and operation
• Bespoke wire feed unit
• External interface with dual channel safety interlock
• Ability to enable the feeder on/off via the torch
• Top mounted control panel for enhanced user experience
• Includes 4.3m torch
• Product demonstrations available
Project Specification
| Material | One Sided Limit Welding Seam |
|---|---|
| Stainless Steel | Up to 3.5mm |
| Carbon Steel | Up to 3.5mm |
| Aluminium | Up to 3mm |
| Galvanised Steel | Up to 3.5mm |
| Brass | Up to 2.5mm |
| Input Power | 230Vac / 50Hz / 32A (Max 3KW) |
| Operating Ambient Temperature (°C) | 0-40 |
| Operating Ambient Humidity | 10 – 85% |
| Storage Temperature (°C) | -10 – 60 |
| Output (100% CW) | 800W |
| Power Regulation Range | 10 – 100% |
| Laser Cooling Method | Phase change heat dissipation |
| Tip Cooling Method | Nitrogen / Argon |
| Operation Mode | CW / Modulated |
| Polarisation | Random |
| Central Wavelength | 1080nm |
| Fibre Width | 20μm |
| Wobble Width | 0 – 6mm |
| Wobble Frequency | 0 – 280Hz |
| Continuous Light Output Time (S) | Light 120S, Stop 6S |
| Weight | 29 kg |
| Dimensions | 588 x 265 x 512mm |
| Optical Fibre Armoured Cable Length | 4.35m |
MA1-35
800W Power
Key Features
• Portable design
• Compact handheld welding torch
• Stable performance and reliable quality
• Six layers of safety protection
• Simple operating system
• Easy installation and operation
• Bespoke wire feed unit
• External interface with dual channel safety interlock
• Ability to enable the feeder on/off via the torch
• Top mounted control panel for enhanced user experience
• Includes 4.3m torch
• Product demonstrations available
Project Specification
| Material | One Sided Limit Welding Seam |
|---|---|
| Stainless Steel | Up to 3.5mm |
| Carbon Steel | Up to 3.5mm |
| Aluminium | Up to 3mm |
| Galvanised Steel | Up to 3.5mm |
| Brass | Up to 2.5mm |
| Input Power | 230Vac / 50Hz / 32A (Max 3KW) |
| Operating Ambient Temperature (°C) | 0-40 |
| Operating Ambient Humidity | 10 – 85% |
| Storage Temperature (°C) | -10 – 60 |
| Output (100% CW) | 800W |
| Power Regulation Range | 10 – 100% |
| Laser Cooling Method | Phase change heat dissipation |
| Tip Cooling Method | Nitrogen / Argon |
| Operation Mode | CW / Modulated |
| Polarisation | Random |
| Central Wavelength | 1080nm |
| Fibre Width | 20μm |
| Wobble Width | 0 – 6mm |
| Wobble Frequency | 0 – 280Hz |
| Continuous Light Output Time (S) | Light 120S, Stop 6S |
| Weight | 29 kg |
| Dimensions | 588 x 265 x 512mm |
| Optical Fibre Armoured Cable Length | 4.35m |
MA1-45
1200W Power
Key Features
• Portable design
• Compact handheld welding torch
• Stable performance and reliable quality
• Six layers of safety protection
• Simple operating system
• Easy installation and operation
• Bespoke wire feed unit
• External interface with dual channel safety interlock
• Includes 5.6m torch
• Product demonstrations available
Project Specification
| Material | One Sided Limit Welding Seam |
|---|---|
| Stainless Steel | Up to 4.5mm |
| Carbon Steel | Up to 4.5mm |
| Aluminium | Up to 4mm |
| Galvanised Steel | Up to 4.5mm |
| Brass | Up to 3.5mm |
| Copper | Up to 1.5mm |
| Input Power | 230Vac / 50Hz / 32A (Max 4.8KW) |
| Operating Ambient Temperature (°C) | 0-40 |
| Operating Ambient Humidity | 10 – 85% |
| Storage Temperature (°C) | -10 – 60 |
| Output (100% CW) | 1200W |
| Power Regulation Range | 10 – 100% |
| Laser Cooling Method | Phase change heat dissipation |
| Tip Cooling Method | Nitrogen / Argon |
| Operation Mode | CW / Modulated |
| Polarisation | Random |
| Central Wavelength | 1080nm |
| Fibre Width | 20μm |
| Wobble Width | 0 – 4mm |
| Wobble Frequency | 0 – 280Hz |
| Continuous Light Output Time (S) | Light 120S, Stop 6S |
| Weight | 38 kg |
| Dimensions | 667 x 276 x 542 mm |
| Optical Fibre Armoured Cable Length | 5.6m |
1500W Power
Key Features
• Portable design
• Compact handheld welding torch
• Stable performance and reliable quality
• Six layers of safety protection
• Simple operating system
• Easy installation and operation
• Bespoke wire feed unit
• External interface with dual channel safety interlock
• External interface suitable for automated applications
• Includes 5.6m torch
• Product demonstrations available
Project Specification
| Material | One Sided Limit Welding Seam |
|---|---|
| Stainless Steel | Up to 6.5mm |
| Carbon Steel | Up to 6.5mm |
| Aluminium | Up to 5.5mm |
| Galvanised Steel | Up to 6.5mm |
| Brass | Up to 4.5mm |
| Copper | Up to 3mm |
| Input Power | 230Vac / 50Hz / 32A (Max 6KW) |
| Operating Ambient Temperature (°C) | 0-40 |
| Operating Ambient Humidity | 10 – 85% |
| Storage Temperature (°C) | -10 – 60 |
| Output (100% CW) | 1500W |
| Power Regulation Range | 10 – 100% |
| Laser Cooling Method | Phase change heat dissipation |
| Tip Cooling Method | Nitrogen / Argon |
| Operation Mode | CW / Modulated |
| Polarisation | Random |
| Central Wavelength | 1080nm |
| Fibre Width | 20μm |
| Wobble Width | 0 – 4mm |
| Wobble Frequency | 0 – 280Hz |
| Continuous Light Output Time (S) | Light 120S, Stop 6S |
| Weight | 38 kg |
| Dimensions | 667 x 276 x 542 mm |
| Optical Fibre Armoured Cable Length | 5.6m |
Laser Welding Torch
680 Grams
Ergonomic Design
Status Indicator
Robust
Single Trigger Operation
QCS Fibre Optic Cable
Status Indicator
QCS Fibre Optic Cable
The use of collimated QCS interface greatly reduces the size and weight of the welding
torch, only 680g. The optical design is perfectly matched with the QCS output head, the
transmission efficiency is high, and the heat generation is small. The welding torch design
is ergonomic, comfortable to hold and easy to operate. In addition, the torch has a built-in
swing function that allows the operator to consistently and safely perform high-quality
welds throughout the day with dual safety light buttons.
THE LIGHTEST AND SMALLEST HANDHELD WELDING TORCH IN THE INDUSTRY
Laser Welding Torch
680 Grams
Ergonomic Design
Status Indicator
Robust
Single Trigger Operation
QCS Fibre Optic Cable
Status Indicator
QCS Fibre Optic Cable
The use of collimated QCS interface greatly reduces the size and weight of the welding
torch, only 680g. The optical design is perfectly matched with the QCS output head, the
transmission efficiency is high, and the heat generation is small. The welding torch design
is ergonomic, comfortable to hold and easy to operate. In addition, the torch has a built-in
swing function that allows the operator to consistently and safely perform high-quality
welds throughout the day with dual safety light buttons.
THE LIGHTEST AND SMALLEST HANDHELD WELDING TORCH IN THE INDUSTRY
T1 Wire Feed Unit
• Exclusive wire feed unit developed and built by
Max Photonics for the MA1 series of machines
• 4 roll drive system ensures smooth wire feeding
• Controlled via user interface of the power source
• Wire inching and retraction control
• Wire spool size D200/D300 up to 25Kg
• Quick release liner connection
• Supports wire feeding speeds from 2-100mm/s
• Continuous and pulse wire feeding options
T1 Wire Feed Unit
• Exclusive wire feed unit developed and built by
Max Photonics for the MA1 series of machines
• 4 roll drive system ensures smooth wire feeding
• Controlled via user interface of the power source
• Wire inching and retraction control
• Wire spool size D200/D300 up to 25Kg
• Quick release liner connection
• Supports wire feeding speeds from 2-100mm/s
• Continuous and pulse wire feeding options
Enclosures
The required safety and personal protection measures must not be overlooked
whilst capitalising on the productivity gains that hand held fibre laser welding
offers. When using a Class 4 laser welder it is imperative that you use a suitable
Class 4 enclosure.
Wilkinson Star Limited supply Class 4 laser welding enclosure solutions to
offer protection to all workers within the workspace.
A Kyrus Laser Welding Enclosure helps mitigate the dangers of hand held
laser welders by providing a safe and contained working environment.
Kyrus have designed a standard “plug and play” range that provides this
safe working environment.
SPECIFICALLY DESIGNED / / INTEGRATED SAFETY / / MODULAR DESIGN
Key Features
• Specifically designed for use with the new generation of hand held
laser welders, and comply to IEC 60825-4 standards
• Integrates with the built in safety systems of your laser welding equipment
• Fully integrated “plug and play” electronics including door interlock,
power distribution, cable trunking and LED lighting
• Modular design, allowing for interchangeable positions and future
expansion capabilities
• Supplied as flat pack and can be easily installed (or for peace
of mind we offer installation as a service)
• Floor seals to prevent visible reflections
• Illuminated laser warning signage
• Available with three external viewing options: CCTV with live screen
(recommended), 4K CCTV with live screen (recommended for
demonstration areas) or optical viewing window
• Light-tight services connection
• Enclosed roof option
• Sliding and hinged door options
• Bespoke enclosure packages/sizes available on request
Enclosures
The required safety and personal protection measures must not be overlooked
whilst capitalising on the productivity gains that hand held fibre laser welding
offers. When using a Class 4 laser welder it is imperative that you use a suitable
Class 4 enclosure.
Wilkinson Star Limited supply Class 4 laser welding enclosure solutions to
offer protection to all workers within the workspace.
A Kyrus Laser Welding Enclosure helps mitigate the dangers of hand held
laser welders by providing a safe and contained working environment.
Kyrus have designed a standard “plug and play” range that provides this
safe working environment.
SPECIFICALLY DESIGNED / / INTEGRATED SAFETY / / MODULAR DESIGN
Key Features
• Specifically designed for use with the new generation of hand held
laser welders, and comply to IEC 60825-4 standards
• Integrates with the built in safety systems of your laser welding equipment
• Fully integrated “plug and play” electronics including door interlock,
power distribution, cable trunking and LED lighting
• Modular design, allowing for interchangeable positions and future
expansion capabilities
• Supplied as flat pack and can be easily installed (or for peace
of mind we offer installation as a service)
• Floor seals to prevent visible reflections
• Illuminated laser warning signage
• Available with three external viewing options: CCTV with live screen
(recommended), 4K CCTV with live screen (recommended for
demonstration areas) or optical viewing window
• Light-tight services connection
• Enclosed roof option
• Sliding and hinged door options
• Bespoke enclosure packages/sizes available on request
Hand Held Laser Welding Enclosure – 3m x 2m
| Order Code | Description |
|---|---|
| KY-LENC-001 | 3m x 2m Enclosure, with 1.2m Hinge Door |
| KY-LENC-001A | 3m x 2m Enclosure, with 1.2m Sliding Door |
| ASM-000137 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 3m x 3m
| Order Code | Description |
|---|---|
| KY-LENC-002 | 3m x 3m Enclosure, with 1.2m Hinge Door |
| KY-LENC-003 | 3m x 3m Enclosure, with 1.3m Sliding Door |
| ASM-000138 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 4m x 3m
| Order Code | Description |
|---|---|
| KY-LENC-004 | 4m x 3m Enclosure, with 1.3m Sliding Door |
| ASM-000140 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 4m x 4m
| Order Code | Description |
|---|---|
| KY-LENC-005 | 4m x 3m Enclosure, with 2m Sliding Door |
| ASM-000139 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 3m x 2m
| Order Code | Description |
|---|---|
| KY-LENC-001 | 3m x 2m Enclosure, with 1.2m Hinge Door |
| KY-LENC-001A | 3m x 2m Enclosure, with 1.2m Sliding Door |
| ASM-000137 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 3m x 3m
| Order Code | Description |
|---|---|
| KY-LENC-002 | 3m x 3m Enclosure, with 1.2m Hinge Door |
| KY-LENC-003 | 3m x 3m Enclosure, with 1.3m Sliding Door |
| ASM-000138 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 4m x 3m
| Order Code | Description |
|---|---|
| KY-LENC-004 | 4m x 3m Enclosure, with 1.3m Sliding Door |
| ASM-000140 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
Hand Held Laser Welding Enclosure – 4m x 4m
| Order Code | Description |
|---|---|
| KY-LENC-005 | 4m x 3m Enclosure, with 2m Sliding Door |
| ASM-000139 | Option: Roofing Module |
| ASM-000136 | Option CCTV Module (recommended) |
| OS-000030 | Option: Optical Viewing Window |
