Product Introduction
Copper laser welding machines are high-performance systems designed to meet the challenges of welding copper and copper alloys—materials known for their high reflectivity and thermal conductivity. Traditional welding methods often struggle with copper due to poor arc stability, excessive heat loss, and inconsistent penetration. Laser welding overcomes these issues by delivering a concentrated beam of energy with precise control, allowing for deep, narrow welds and minimal heat distortion. These machines are ideal for industries that demand conductivity, strength, and precision, such as electrical engineering, battery production, automotive electronics, and renewable energy systems. They are commonly used to weld copper busbars, motor coils, battery tabs, heat exchangers, and fine electronic components with high repeatability and minimal post-processing. Copper laser welding machines typically use high-power fiber or green lasers optimized for copper’s properties, and often include real-time monitoring systems and CNC or robotic integration for fully automated operation. With fast cycle times, clean seams, and superior control over thermal input, these machines deliver reliable, high-quality results where other welding methods fall short. They are essential tools for modern manufacturing environments focused on energy efficiency, miniaturization, and electrical performance.
Types of Copper Laser Welding Machines
-
Standard Handheld Laser Welding Machine
Price range: $3,400.00 through $16,000.00 This product has multiple variants. The options may be chosen on the product page -
Portable Handheld Laser Welding Machine
Price range: $3,700.00 through $15,500.00 This product has multiple variants. The options may be chosen on the product page -
3 in 1 Handheld Laser Welding Machine
Price range: $4,000.00 through $15,700.00 This product has multiple variants. The options may be chosen on the product page -
Double Wobble Handheld Laser Welding Machine
Price range: $3,900.00 through $16,500.00 This product has multiple variants. The options may be chosen on the product page -
Double Wire Feed Handheld Laser Welding Machine
Price range: $6,800.00 through $15,800.00 This product has multiple variants. The options may be chosen on the product page -
Air-Cooled Handheld Laser Welding Machine
Price range: $4,900.00 through $6,900.00 This product has multiple variants. The options may be chosen on the product page -
3 in 1 Air-Cooled Handheld Laser Welding Machine
Price range: $5,100.00 through $7,100.00 This product has multiple variants. The options may be chosen on the product page -
Automatic Laser Welding Platform
Price range: $9,800.00 through $21,500.00 This product has multiple variants. The options may be chosen on the product page
Welding Thickness Reference
| Laser Power | Welding Form | Thickness | Welding Speed | Defocus Amount | Protective Gas | Blowing Method | Flow | Welding Effect |
|---|---|---|---|---|---|---|---|---|
| 1500W | Butt Welding | 0.5mm | 40~50 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely |
| 2000W | Butt Welding | 0.5mm | 60~70 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely |
| Butt Welding | 1mm | 20~30 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| 3000W | Butt Welding | 0.5mm | 60~70 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely |
| Butt Welding | 1mm | 40~50 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| Butt Welding | 1.5mm | 30~40 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| Butt Welding | 2mm | 20~30 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| 6000W | Butt Welding | 0.5mm | 60~70 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely |
| Butt Welding | 1mm | 50~60 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| Butt Welding | 1.5mm | 40~50 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely | |
| Butt Welding | 2mm | 30~40 mm/s | -1~1 | Ar | Coaxial/Paraaxial | 5~10 L/min | Welded Completely |
Compatible Copper Grades
- C10100
- C10200
- C10300
- C10400
- C10500
- C10700
- C10800
- C11000
- C11300
- C11400
- C11500
- C11600
- C12000
- C12200
- C12300
- C14200
- C15100
- C15500
- C16200
- C16500
- C17000
- C17200
- C17500
- C17510
- C18000
- C18100
- C18200
- C19200
- C19400
- C19700
- C21000
- C22000
- C23000
- C24000
- C26000
- C27000
- C28000
- Cu-ETP
- Cu-DHP
- Cu-HCP
Application of Copper Laser Welding Machines
Copper laser welding machines are essential in industries that require high electrical and thermal conductivity, along with precision and durability. In the electrical and electronics sectors, they are widely used for welding motor windings, copper busbars, connectors, PCB components, and transformer coils, where reliable, low-resistance joints are critical. In battery manufacturing—especially for electric vehicles and energy storage systems—laser welding is ideal for joining copper tabs, terminals, and current collectors with minimal heat distortion. The renewable energy industry uses these machines to weld copper parts in solar panels, inverters, and power systems. They are also employed in aerospace and automotive sectors for fabricating sensors, harnesses, and conductive assemblies that demand lightweight, high-performance materials. Laser welding ensures minimal oxidation, clean seams, and tight control over heat input, making it ideal for copper’s high reflectivity and conductivity. With robotic integration and high-speed capability, these machines support both precision prototyping and high-volume production.
Customer Testimonials
Comparison VS Other Welding Technologies
| Comparison Item | Laser Welding | MIG Welding | TIG Welding | Stick Welding |
|---|---|---|---|---|
| Heat Input | Low (precise control, minimal distortion) | High (risk of overheating, distortion) | Moderate to High | High (excessive heat) |
| Weld Speed | Very High | High | Low | Moderate |
| Weld Precision | Extremely High | Moderate | High | Low |
| Reflectivity Handling | Excellent (esp. with fiber or green lasers) | Poor (unstable arc on shiny surface) | Poor to Moderate | Poor |
| Porosity Risk | Low (with proper parameters) | High (poor fusion common) | Moderate | High |
| Surface Preparation Sensitivity | Moderate | High | High | Very High |
| Suitable for Thin Sections | Excellent | Poor (burn-through risk) | Good | Poor |
| Post-Weld Cleaning | Minimal | High (spatter, oxidation) | Moderate | High (slag, oxidation) |
| Joint Appearance | Clean, smooth | Rough (often needs finishing) | Good | Rough and uneven |
| Automation Compatibility | Excellent (CNC/robot ready) | Good | Limited | Not compatible |
| Operator Skill Requirement | Moderate (with automation) | Moderate | High | Low to Moderate |
| Electrical Conductivity Retention | Excellent | Moderate (possible microcracks/voids) | Good | Poor |
| Production Throughput | Very High | High | Low | Moderate |
| Initial Equipment Cost | High | Moderate | Moderate | Low |
| Operating Cost | Low (efficient, minimal rework) | Moderate | High (slow, gas-intensive) | Low |
Why Choose Us
AccTek Group is a professional manufacturer of laser welding machines, delivering precise, efficient, and reliable welding solutions for a wide range of industries. Our machines are designed to meet the growing demand for high-strength, low-distortion welding in applications such as sheet metal processing, automotive manufacturing, electronics, and aerospace. We combine advanced laser technology with user-friendly design to help businesses improve welding quality, reduce labor costs, and boost production efficiency. Whether you’re handling fine parts or large-scale components, our systems offer the flexibility and performance needed to meet modern manufacturing standards. With a strong focus on quality, innovation, and customer support, AccTek Group is your trusted partner for laser welding solutions.
High Precision
Our machines deliver accurate, clean welds with minimal heat input, reducing distortion and ensuring strong, consistent joints across a wide range of materials and thicknesses.
Easy Operation
Designed with intuitive controls and user-friendly interfaces, our systems allow both experienced operators and new users to achieve professional results with minimal training.
Durable & Reliable
Built with high-quality components and strict quality standards, our welding machines provide stable performance, long service life, and low maintenance requirements.
Custom Options
We offer a variety of models and customizable features to match specific production needs, helping businesses improve workflow and adapt to changing manufacturing demands.
Related Resources
What Materials Can Be Welded With Lasers?
2025-07-07
This article explores the wide range of materials that can be welded using lasers, covering metals, non-metals, composites, and key factors that affect weldability.
Laser Welding VS TIG Welding
2025-06-19
This article compares laser welding and TIG welding across key factors, including process, equipment, applications, costs, and suitability for various industries.
Laser Welding VS MIG Welding
2025-06-01
This article compares laser welding and MIG welding in terms of process, applications, cost, quality, and efficiency to help readers understand their key differences.
What Is Laser Welding?
2025-05-08
Explore the principles of laser welding, its benefits, applications, and how it compares to traditional welding methods. Learn how this advanced technology enhances precision and efficiency.
Frequently Asked Questions
Why Is It So Difficult To Weld Copper With Lasers?
Laser welding copper is notably challenging due to the metal’s unique physical properties, which resist consistent energy absorption and stable weld formation. The difficulties aren’t due to a flaw in the laser itself but rather the way copper behaves under concentrated light and heat.
- Extremely High Reflectivity: Copper reflects over 95% of laser light in the near-infrared spectrum, especially at room temperature. That means most of the energy from traditional fiber or CO2 lasers simply bounces off the surface instead of being absorbed. The laser has to “punch through” this reflectivity to begin melting the material, requiring extremely high energy densities or ultra-short pulses.
- Rapid Heat Conductivity: Once the copper begins to absorb energy, it transfers heat away from the weld zone almost instantly. Copper has one of the highest thermal conductivities of any metal. This causes a localized cooling effect that makes it hard to keep the weld pool molten. The result is shallow penetration, incomplete fusion, and inconsistent weld seams, especially in thicker parts.
- Narrow Thermal Processing Window: Copper has a relatively narrow solidification range, which means the molten metal transitions from liquid to solid very quickly. This makes it prone to hot cracking and porosity, especially when the heat input is not perfectly controlled. Small variations in speed, power, or shielding can lead to defects.
- Surface Oxidation and Contaminants: Copper readily oxidizes in air. This oxide layer further increases reflectivity and acts as a barrier to clean fusion. Even thin films of oil or moisture can destabilize the process, making surface cleaning and inert shielding gas (typically argon or helium) essential for quality welds.
What Are The Advantages Of Laser Welding Copper?
Laser welding copper offers significant advantages, particularly for industries that require precision, speed, and reliability in joining highly conductive and reflective materials. Despite its challenges, copper responds well to laser welding under the right conditions, and the benefits are notable when compared to traditional methods.
- Precision and Minimal Heat Affected Zone (HAZ): Laser welding allows for pinpoint accuracy with a narrow, concentrated heat input. This is especially important with copper, as excessive heat can distort delicate components or damage neighboring materials. The minimal HAZ helps preserve the electrical and mechanical properties of the material.
- High-Speed, Automated Processing: Laser welding systems can operate at very high speeds, making them ideal for large-scale or repetitive manufacturing. This is especially valuable in sectors like electric vehicle battery production or electronics assembly, where copper is widely used and volume is high.
- Clean, Consistent Welds: When parameters are optimized, laser welding can produce highly uniform seams with minimal spatter or post-processing needs. This is especially useful in micro-welding applications such as joining copper terminals, thin foils, or conductors, where cleanliness and consistency are critical.
- Non-Contact Process: Because laser welding doesn’t require physical contact with the workpiece, there is less wear on equipment and reduced risk of introducing contamination. This also allows for welding in hard-to-reach or sensitive areas, such as inside compact housings or electronic modules.
- Better Control Over Energy Input: Laser welding systems can be finely tuned for pulse duration, beam shape, and power levels. This allows engineers to tailor the energy input precisely for copper’s unique thermal properties, helping to avoid defects like cracking, porosity, or insufficient fusion.
- Reduced Risk of Cross-Contamination: Unlike arc or resistance welding, laser welding doesn’t require filler metals or electrodes that can introduce foreign materials into the joint. This is a key benefit when working with copper in electrical systems, where conductivity and purity are crucial.
- Compatible With Modern Copper Alloys: Many copper-based materials used in manufacturing are alloyed for better strength or corrosion resistance. Laser welding is well-suited for joining these engineered materials, especially when assisted by green lasers or fiber lasers optimized for copper.
What Gases Are Used For Laser Welding Copper?
Laser welding copper requires a carefully controlled environment, and shielding gases play a crucial role in achieving clean, high-quality welds. Due to copper’s high reflectivity and thermal conductivity, the choice of gas affects not only weld quality but also the stability of the process. Here are the most commonly used gases for laser welding copper:
- Argon: Argon is the most widely used shielding gas in copper laser welding. It’s chemically inert, meaning it won’t react with the molten metal, and it effectively displaces atmospheric oxygen and nitrogen that could cause oxidation or porosity. Argon helps produce smooth, consistent welds with minimal surface contamination. It’s especially useful in pulsed laser welding where tight control over the weld zone is needed.
- Helium: Helium is sometimes used on its own or mixed with argon. It offers higher thermal conductivity and ionization potential, which helps stabilize the laser arc and allows deeper penetration in some copper alloys. However, helium is more expensive than argon, so it’s often reserved for critical applications like fine electronic connections or where porosity is a concern.
- Argon-Helium Mixtures: Mixing helium with argon combines the arc-stabilizing benefits of helium with the shielding performance and cost-effectiveness of argon. Common mixtures include 75% argon/25% helium or 90% argon/10% helium. These blends can enhance fusion depth and improve flow in the weld pool, especially useful in continuous wave fiber laser welding.
- Nitrogen (Limited Use): Nitrogen is generally avoided when welding copper due to its tendency to react at high temperatures and form porosity or brittle compounds. However, in some specific copper alloys and when used in small concentrations as part of a mixture, nitrogen may help improve arc stability. Its use requires precise control and alloy compatibility testing.
What Pre-Cleaning Steps Are Required Before Laser Welding Copper?
Laser welding copper presents unique challenges due to the metal’s high reflectivity, thermal conductivity, and sensitivity to surface contamination. Proper pre-cleaning is essential to ensure strong, reliable welds with minimal defects such as porosity, poor fusion, or spatter. Here are the critical pre-cleaning steps required before laser welding copper:
- Surface Degreasing: Copper often comes coated with oils or lubricants from machining or storage. These residues can vaporize during welding and form voids or oxidation in the weld pool.
- Use isopropyl alcohol, acetone, or a dedicated industrial degreaser to remove oils.
- Apply with lint-free cloths or ultrasonic cleaners for small, intricate parts.
- Ensure the surface is dry before proceeding.
- Oxide Layer Removal: Copper quickly forms a thin oxide layer (cuprous and cupric oxide) when exposed to air. These oxides can interfere with laser energy absorption and reduce weld quality.
- Light abrasion with a stainless steel brush, Scotch-Brite pad, or fine-grit abrasive paper (320–600 grit) is effective.
- For higher-volume or automated lines, laser or plasma cleaning systems may be used.
- Avoid using regular steel brushes, as they can introduce iron contamination that may lead to corrosion.
- Chemical Cleaning (Optional but Effective): For precision applications, chemical etching can remove both organic residues and oxides.
- Acid solutions like dilute sulfuric acid or citric acid can be used, followed by thorough rinsing and drying.
- This step is more common in microelectronics or battery welding, where surface purity is critical.
- Surface Drying and Handling: After cleaning, surfaces must be completely dry and kept clean before welding.
- Use compressed air or low-temperature drying ovens to remove moisture.
- Avoid touching the cleaned surface with bare hands—wear clean gloves to prevent re-contamination.
- Store pre-cleaned copper in sealed containers or inert environments if there’s a delay before welding.
- Fixture Cleanliness: Welding fixtures or clamps must also be clean to avoid transferring contaminants to the workpiece. Residue from dirty fixtures can undo cleaning efforts and affect weld consistency.
How Thick Copper Can Be Welded With Lasers?
Laser welding of copper is technically demanding but increasingly feasible with the right equipment and techniques. Due to copper’s high thermal conductivity and reflectivity, laser power must be carefully matched to the material thickness to achieve stable penetration without overheating or surface instability. Below are typical welding thickness capacities for copper based on laser power:
- 1500W Laser: This power level is typically suited for ultra-thin copper components, around 0.5 mm thick.
- Applications: Fine electrical contacts, flexible circuit tabs, and small battery tabs.
- Welding Strategy: Often requires high-speed scanning to prevent overheating and reduce spatter.
- 2000W Laser: A 2000W laser can handle copper thicknesses up to 1 mm under well-optimized conditions.
- Applications: PCB shielding cases, battery busbars, or power connectors.
- Tips: Use short focal lengths and clean copper surfaces to improve absorption and reduce beam reflection.
- 3000W Laser: At 3000W, copper sections up to 2 mm thick can be welded consistently.
- Applications: Heavier connectors, ground plates, and larger electrical enclosures.
- Note: Preheating or multi-pass techniques may be used to improve penetration depth and weld stability.
- 6000W Laser: Surprisingly, even at 6000W, the maximum thickness reliably welded remains around 2 mm, especially in single-pass modes.
- Reason: Beyond 2 mm, copper’s rapid heat dissipation and low absorption (especially in solid state) make full penetration challenging.
- Approach: May require pulse shaping, tailored optics, or copper alloy substitution (e.g., CuCrZr) to increase weldability.
How Much Do Copper Laser Welding Machines Cost?
Laser welding machines for copper vary widely in price depending on their configuration, power level, automation features, and intended use. While handheld units are more affordable and flexible, automated systems are designed for high-volume or precision applications and come with a higher investment. Here’s a breakdown of typical price ranges:
- Handheld Copper Laser Welding Machines: These are compact, portable systems that are often used for maintenance, small-scale fabrication, or light production.
- Price Range: $3,500–$18,000
- Key Features: Air-cooled or water-cooled, typically 1000W to 2000W fiber lasers, simple interface, and plug-and-play setup.
- Use Cases: Repairing copper pipe joints, joining battery tabs, small electrical assemblies, and hobbyist work.
- Pros: Low entry cost, minimal setup, flexible for different job sizes.
- Cons: Limited automation, less consistent for repeatable weld quality on high-reflectivity materials like copper.
- Automatic Copper Laser Welding Machines: These systems are built for production environments with robotic arms, CNC gantries, or custom jigs for part positioning.
- Price Range: $10,000–$30,000
- Key Features: Higher laser powers (up to 6000W), vision-guided systems, programmable paths, cooling systems, and fume extraction integration.
- Use Cases: EV battery manufacturing, busbar welding, copper enclosures, electrical switchgear, and PCB frame welding.
- Pros: High precision, repeatability, and throughput; safer for operators; easier integration into production lines.
- Cons: Larger footprint, higher upfront cost, more training required.
How To Reduce Spatter When Laser Welding Copper?
Laser welding copper presents a unique set of challenges—chief among them is spatter. Due to copper’s high thermal conductivity and reflectivity, controlling melt pool behavior is critical. Excessive spatter can reduce weld quality, contaminate optics, and damage surrounding surfaces. Here’s how to effectively reduce it:
- Laser Power and Pulse Control: High power density can lead to deep keyhole formation and violent melt pool dynamics, both of which increase spatter.
- Use lower peak power with longer pulse durations if using pulsed lasers.
- For continuous wave lasers, ramp up power gradually rather than blasting full power at the start.
- Modulate the waveform or use pulsed waveform shaping to stabilize the melt pool and reduce turbulence.
- Beam Position and Focus Optimization: The focus position directly affects energy absorption and melt pool stability.
- Slightly defocus the beam (positive offset above the surface) to broaden the interaction area and reduce peak intensity.
- Maintain precise alignment with the joint to avoid asymmetric heating that promotes spatter.
- Shielding Gas Selection and Flow Direction: Proper shielding gas not only protects the weld from oxidation but also helps suppress spatter.
- Use argon or a helium-argon mix to stabilize the arc and improve weld cleanliness.
- Direct the gas at a shallow angle toward the weld to guide spatter away without disturbing the melt pool.
- Avoid excessive flow rates that can create turbulence and scatter molten droplets.
- Surface Preparation: Dirty, oxidized, or contaminated copper amplifies instability during welding.
- Mechanically or chemically clean the surface beforehand to remove oxides, oils, and particulates.
- Even thin oxide films can cause localized overheating, triggering micro-explosions and ejecting molten metal.
- Welding Speed and Travel Control: Travel speed affects heat input and molten pool behavior.
- Too slow = overheating and larger melt pools = more spatter.
- Too fast = incomplete fusion and erratic spatter.
- Find the sweet spot for speed-to-power ratio through trials or vendor-recommended process windows.
- Laser Type Matters: If spatter is persistent, consider upgrading the source.
- Green lasers (532 nm) and blue lasers (450 nm) offer better absorption in copper, resulting in more stable melting and dramatically less spatter compared to traditional near-infrared fiber lasers.
How To Maintain Copper Laser Welding Machines?
Copper laser welding machines require diligent maintenance due to copper’s high reflectivity and thermal conductivity, which place extra demand on the equipment. Proper care ensures consistent weld quality, minimizes downtime, and extends machine lifespan. Here are the key maintenance practices:
- Optics and Protective Glass: Laser optics (like focusing lenses and protective windows) are vulnerable to contamination from copper vapor and spatter.
- Inspect lenses and protective covers frequently for dirt, pitting, or discoloration.
- Clean them using lens-safe solvents and non-abrasive wipes.
- Replace any damaged optics immediately to maintain beam quality and prevent further equipment damage.
- Shielding Gas System: High-purity argon or helium is commonly used to shield copper welds from oxidation.
- Check hoses and connectors for leaks or blockages.
- Maintain proper gas flow rates using clean and calibrated flow meters.
- Replace gas filters regularly to avoid contamination.
- Cooling Unit: Laser welding systems generate significant heat, and overheating is a risk when welding copper.
- Monitor coolant levels and top off with manufacturer-recommended fluids.
- Clean the chiller and replace filters as needed.
- Watch for temperature alarms and respond promptly.
- Nozzle and Head Maintenance: Spatter buildup can obstruct the nozzle and reduce weld precision.
- Clean nozzles with appropriate tools after each use.
- Inspect for wear and replace damaged parts to maintain stable gas coverage and weld consistency.
- Check the alignment and tightness of welding heads regularly.
- Software, Alignment, and Diagnostics: Regularly calibrate the laser beam and head position to ensure weld precision.
- Update the control software and firmware when new versions become available.
- Use built-in diagnostics to monitor laser power output and system performance.
- Dust and Contamination Control: Copper particles and dust can damage sensitive components.
- Clean work surfaces, filters, and fans regularly.
- Vacuum dust from the machine housing using anti-static equipment.
- Avoid operating in high-humidity or poorly ventilated areas.
- Electrical Components and Safety Checks: Tighten electrical connectors and inspect for insulation damage or loose wires.
- Test emergency stops, interlocks, and safety lights to ensure full system protection.
- Store maintenance logs and address issues early before they escalate.
Get Copper Welding Solutions
Maximize the potential of copper welding with our copper laser welding machines, engineered to provide precise, high-quality welds for this challenging yet highly versatile material. Copper’s excellent thermal conductivity and high melting point make it difficult to weld, but our advanced laser technology ensures flawless results with minimal distortion and maximum efficiency. Ideal for industries such as electronics, automotive, and manufacturing, these machines offer superior control and precision to achieve strong, durable joints.
Our copper laser welding machines excel at minimizing heat-affected zones and preventing material warping, which is essential for maintaining the integrity of the workpiece. The result is a clean, smooth finish with reduced oxidation and minimal post-weld processing.
With adjustable settings and automated features, our machines offer flexibility for various copper welding applications, from delicate components to large-scale production runs. Designed for reliability and longevity, our solutions provide high performance and cost-efficiency, helping you achieve top-tier copper welds every time.
* We value your privacy. AccTek Group is committed to protecting your personal information. Any details you provide when submitting the form will be kept strictly confidential and used only to assist with your inquiry. We do not share, sell, or disclose your information to third parties. Your data is securely stored and handled by our privacy policy.