Distortion has long been the unwelcome companion of welding—especially when working with thick sections of high-value materials like stainless steel. Fabricators, welders, and engineers alike have had to accept it as part of the process, spending significant time and resources trying to manage it. But with the arrival of pure laser welding enabled by Dynamic Beam Lasers (DBL) , the rules are changing. It is now possible to achieve single-pass welds in thick materials with virtually no distortion —and without the heavy fixturing traditionally required. The Real Cost of Distortion Distortion in welding doesn’t just affect the weld seam—it affects the entire fabrication process. Misaligned parts, warped structures, and internal stress buildup can lead to a cascade of problems: assemblies that don’t fit, components that must be reworked or scrapped, and significant delays in production timelines. In sectors like shipbuilding, energy infrastructure, aerospace, and defense, where precision is critical and tolerances are tight, distortion can become a showstopper. The response has been to engineer around the problem. Welders and engineers apply numerous techniques and best practices to keep distortion under control—but none of them eliminate it entirely. Instead, these methods often add cost and complexity to every project. How Welders Manage Distortion Today To control distortion, welders rely on a mix of experience, technique, and tooling. They minimize the size and volume of welds, use intermittent or skip welding instead of continuous welds, and plan sequences that distribute heat evenly. In more challenging cases, they employ backstep welding, pre-bend parts (presetting), or clamp components tightly with jigs and strongbacks. Post-weld, peening or thermal stress relief may be used to reduce residual stresses. These approaches can work—but they come at a cost. Fixturing adds setup time. Sequencing demands expertise. And post-weld corrections increase labor and lead times. For complex or large structures, the distortion management process can consume more resources than the welding itself. What Causes Distortion? At its core, distortion is the result of uncontrolled thermal expansion and contraction . Welding introduces concentrated heat into a localized area, causing that area to expand. As it cools, the metal contracts—but not always evenly. This uneven thermal cycle creates internal stresses that the material resolves by shifting or warping. Several factors influence the severity of distortion: Localized Heating : When only a small area is heated, it expands against the restraint of the surrounding cooler metal, building up stress. Uneven Cooling : Variability in cooling rates across a part causes some regions to contract more than others, pulling the structure out of shape. Residual Stresses : The combination of compressive and tensile stresses during welding often results in permanent deformation. Material Properties : Metals like stainless steel, with a high coefficient of thermal expansion, are more prone to distortion than others. Unbalanced Weld Design : Welding only one side of a joint or following a poor sequence can concentrate stress on one side. High Heat Input : The more energy introduced into the workpiece—especially through multi-pass welding—the more distortion will occur. The traditional solution has been to work around these issues. But what if you could eliminate them at the source? Pure Laser Welding: A Different Approach Dynamic Beam Lasers (DBL) offer a fundamentally different way to weld thick sections. Unlike conventional lasers or arc welding processes, DBL allows the shape and distribution of the beam to be controlled in real time. This unlocks pure laser welding : a single, stable, full-penetration weld made with ultra-low heat input. With DBL, the laser delivers energy precisely where it's needed—deep into the joint—without overheating the surrounding material. The result is a narrow, deep fusion zone with a very small heat-affected area. By reducing the total thermal input, the thermal expansion and contraction are dramatically reduced. In other words, the root cause of distortion is effectively eliminated. Pure laser welding of 25mm stainless steel structure Case Study: Welding 25mm Stainless Steel Without Fixtures A recent demonstration of DBL’s capability involved welding a 25mm thick stainless steel (SS316) plate . In traditional welding, such a task would require multiple passes, significant clamping, and careful sequencing to manage distortion. In this case, only simple tack welds  were used to hold the plates in place— no external clamps, jigs, or fixtures . The result was striking: A single-pass No measurable distortion  in the final part No post-weld straightening  required A structure that remained perfectly aligned from start to finish This is more than a technical achievement. It’s a practical demonstration of how pure laser welding with DBL can simplify assembly , reduce setup time , and ensure higher quality —even in the most challenging applications. 25mm stainless steel structure welded with a Pure Laser Process Rethinking What’s Possible For decades, distortion has been treated as a problem to be managed. Now, with pure laser welding powered by Dynamic Beam Lasers, it’s a problem that can be eliminated . Fabricators can build large, complex structures without the need for heavy fixtures, elaborate welding plans, or costly rework. Precision is achieved through control—not compensation. In industries where every millimeter counts and every hour matters, this is more than innovation—it’s a revolution.

Welding is a fundamental process in manufacturing across a wide range of industries, serving as a key element in production. For instance, ships often require 300 to 600 kilometers of weld seams to ensure structural integrity. During World War II, the U.S. drastically accelerated ship production by adopting submerged arc welding, which became a pivotal technology for meeting urgent construction demands. As industries continue to advance, innovations in welding technology hold the potential to dramatically increase efficiency. Enhancing welding methods by a factor of 10 or 20 could transform sectors like shipbuilding, renewable energy, and construction by lowering costs and reducing production time. Since the introduction of submerged arc welding, one of the most important advancements has been the development of hybrid welding processes that combine laser technology with Metal Inert Gas/Metal Active Gas (MIG/MAG) welding. This hybrid process offers the ability to achieve relatively large penetration depths, typically around 15 mm, which is sufficient for many industrial applications. By merging the precision of laser technology with the robustness of MIG/MAG welding, the hybrid process provides an improvement in speed and penetration over traditional methods, though it still faces limitations when working with even thicker materials or when further energy efficiency is required. Illustration of welding ship panels with Dynamic Beam Laser   However, despite these advancements, the hybrid process still shares several similarities with traditional arc welding methods, bringing with it some of the same challenges:   1. High Heat Input : Similar to arc welding, hybrid welding generates a high heat input, which can lead to material distortion and the formation of a large Heat-Affected Zone (HAZ). This distortion poses challenges in maintaining proper part alignment and need for large fixturing, requiring additional effort and control measures to mitigate these issues during production. 2. Consumable-Based Process : The hybrid process relies heavily on consumables such as filler materials and protective gases, which add significant cost to the operation. This also contributes to a larger carbon footprint, as the consumption of these materials results in higher CO2 emissions. 3. Complex Joint Preparation (Beveling) : Similar to arc welding, the hybrid method often requires beveling, which involves additional material preparation to ensure proper joint alignment. This beveling process is more complex, time-consuming, and costly, further slowing down production and increasing overall expenses. These challenges make it clear that while hybrid welding offers improvements in certain areas, it still retains many of the drawbacks of traditional welding techniques.     Autogenous weld of 15mm mild steel with minimal distortion  Dynamic Beam Lasers: A Breakthrough for Thick Section Welding Dynamic Beam Lasers (DBL) offer a transformative solution to these challenges. Unlike traditional lasers, which produce a static beam, DBLs can dynamically adjust the beam's shape, intensity, and size in real-time. This flexibility makes them highly effective for welding thick sections of metal, providing increased precision, control, and efficiency. Key Advantages of Dynamic Beam Lasers The introduction of DBL technology has the potential to revolutionize thick section welding, offering significant improvements in speed, energy efficiency, and material usage:   - Increased Welding Speed : DBLs enhance welding speed by achieving greater penetration depth, eliminating the need for multi-layer welding. This reduces production times and accelerates project completion. - Reduced Energy Consumption : DBL technology can decrease energy use by using less passes to weld the same part, making the process more cost-effective and environmentally sustainable. - Lower Gas and Filler Material Requirements : The use of protective gas is significantly reduced, and the laser process eliminates the need for filler material altogether, leading to substantial cost savings and a reduced carbon footprint. Real-World Application: One of the most exciting real-world applications of Dynamic Beam Laser technology is in the shipbuilding industry. Fincantieri S.p.A., a leader in high-value ship construction, is collaborating with Civan Lasers to test DBL for welding thick sections of steel. Traditionally, Fincantieri used a combination of Hybrid Laser and MIG/MAG processes for welding, but these methods have limitations in terms of speed, energy consumption, and the maximum thickness they can weld. Through their open innovation approach, Fincantieri is testing DBL to overcome these challenges.   The early results of this collaboration have been promising: - 40% Increase in Welding Speed : The introduction of DBL has accelerated the welding process, making production more efficient. - Ability to Weld Thicker Sections : DBLs can handle materials that are over twice as thick as those welded by traditional methods, expanding the possibilities for ship design and construction. - 60% Energy Reduction : With less energy required, the process is not only more cost-effective but also aligns with the industry’s sustainability goals. -  90% Reduction in Filler Material Use : The significant drop in filler material consumption drastically reduces costs, streamlining production. - Minimized Use of Protective Gases : Protective gases, which are typically used in large quantities, are no longer a major cost factor.   This collaboration between Fincantieri, Civan, and Castellini exemplifies how DBL technology can be successfully integrated into existing production processes to address traditional limitations, setting a new standard for welding thick sections. Fincantieri S.p.A results with Dynamic Beam Laser    The Future of Thick Section Welding with Dynamic Beam Lasers Dynamic Beam Laser technology is on the cusp of transforming the way thick section welding is done across multiple industries. The advantages—ranging from increased speed and reduced costs to energy efficiency and expanded material capabilities—are game-changing. By adopting DBL technology, industries can not only reduce production times and operational costs but also significantly enhance the quality and strength of the welded structures. As seen in Fincantieri's collaboration, the future of welding thick sections lies in leveraging the precision, flexibility, and efficiency of DBLs to meet the evolving demands of modern manufacturing. With the potential to scale production by a factor of 10 or 20, Dynamic Beam Lasers could revolutionize the way industries approach welding, creating more sustainable, cost-effective, and efficient processes across the board. DBL can achieve welds of up to 70mm thick

Civan Lasers, a global innovator in high-power laser technology, proudly announces its receipt of prestigious award. The company was recognized with the William M. Steen Award for Innovation in Laser Technology at the International Congress on Applications of Lasers & Electro-Optics (ICALEO) and celebrated Fincantieri’s (leading shipyard) reception of the SMAU Innovation Award in Milan, awarded for developing a breakthrough welding process using Civan’s laser technology.   The SMAU Innovation Award is especially meaningful, as it acknowledges Civan’s technology’s real-world impact in welding applications. This award, presented to Fincantieri for their pioneering work in developing a pure laser welding process for ship panels, highlights the industry’s new standard enabled by Civan’s DBL technology. SMAU innovation award ceremony Civan’s DBL has enabled Fincantieri and Castellini to achieve certified welds on ship panels ranging from 5mm to 25mm in thickness through an innovative pure laser welding process. The DBL’s high-power, dynamic beam-shaping capabilities allow operators to tailor the beam to achieve high-quality welds even in thick sections, ensuring deep penetration, reduced thermal distortion, and enhanced material integrity. This efficiency not only improves weld consistency but also significantly reduces costs by saving on consumables and lowering power consumption. Additionally, the ability to weld faster and handle thicker materials greatly increases production efficiency.   By adopting a pure laser-based welding process using Civan’s DBL technology, Fincantieri has achieved transformative results that point to the potential for future industrialization and widespread adoption. Compared to traditional methods, this process offers substantial improvements in efficiency, energy savings, and reduced consumable usage. Initial outcomes reveal a 40% increase in welding speed and a doubling of weldable thickness. Additionally, the DBL process has led to a 60% reduction in energy consumption and up to a 90% decrease in filler material usage, making it a highly cost-effective and eco-friendly solution for demanding industrial applications.    The William M. Steen Award for Innovation in Laser Technology celebrates Civan’s third-generation 120kW Dynamic Beam Laser (DBL), marking a breakthrough in laser technology tailored for industrial readiness. This latest generation incorporates transformative advancements not only in power but also in reliability, compactness, and durability—key improvements for demanding industrial environments. “We are honored to receive the William M. Steen Award and to see our technology drive success for customers like Fincantieri, as celebrated by the SMAU Innovation Award,” said Dr. Eyal Shekel, CEO of Civan Lasers. “Our collaboration with Fincantieri and Castellini demonstrates how Civan’s Dynamic Beam Laser exceeds industry demands, delivering faster, stronger, and more sustainable solutions for sectors where efficiency and resilience are critical.”   With its high power and adaptive beam-shaping capabilities, Civan’s DBL technology reflects the company’s commitment to advancing materials processing. Both the SMAU and William M. Steen Awards recognize Civan’s success in enabling industries to achieve superior production quality and sustainability.

Civan Lasers has an history of pushing the boundaries of laser technology. From the early days of our 1kW systems to the state-of-the-art 120kW Gen III lasers, our journey has been marked by innovation, continuous improvement, and a relentless pursuit of excellence. Let's take a closer look at how our laser systems have evolved over the years. Civan Lasers company history Generation I: The Beginning of a New Era Our journey began with the introduction of the Gen I lasers. These early systems, while revolutionary at the time, had their share of challenges: Power Output : Starting with 1kW in 2012, we quickly advanced to 5kW in 2016 and 14kW by 2018. Dynamic Beam Performance : Although groundbreaking, the initial dynamic beam performance was limited. Reliability : High maintenance needs were a common issue, but these early systems laid the groundwork for future innovations. Despite these challenges, Gen I lasers were a crucial step in our journey, providing valuable insights and establishing our reputation in the laser industry. Generation II: Scaling New Heights The introduction of the Gen II lasers in 2021 marked a significant leap forward. With these systems, we addressed many of the issues faced by their predecessors: Higher Power : The Gen II lasers reached an impressive 100kW, a significant increase from the Gen I systems. Improved Reliability : Through rigorous testing and feedback from top research institutes, we managed to reduce system bugs and enhance overall reliability. Enhanced Dynamic Beam Performance : The dynamic beam performance saw marked improvements, making these lasers more versatile and efficient. The Gen II lasers proved their mettle in various industrial applications, from welding thick sections to remote cutting. They were the backbone of many successful projects, providing the robustness and power required for demanding tasks. Generation III: Setting New Standards Building on the success and lessons learned from Gen I and Gen II, our Generation III lasers represent a new standard in laser technology: Compact Design : One of the most notable advancements is the significant reduction in size and weight. The new power supplies and optical head designs have made the Gen III lasers far more compact and easier to integrate into various applications. Higher Power Output : The 120kW Gen III lasers deliver unparalleled power, pushing the boundaries of what’s possible in laser technology. Enhanced Reliability : Through extensive software and hardware improvements, we’ve achieved unprecedented reliability. A nine-month project tracking over 20 laser systems resulted in an 80% reduction in laser faults. Comparison between 100kW class lasers according to generation Real-World Impact and Case Studies The Gen III lasers have already proven their worth in various high-stakes applications: Ship Panel Welding : Welding times have been reduced by up to 50 times compared to traditional methods. Wind Tower Welding : Similarly, welding times for wind towers are up to 20 times faster, showcasing the efficiency and power of the Gen III systems. Remote Cutting : We’ve demonstrated the ability to cut 100mm mild steel from a distance of 25 meters, highlighting the precision and power of our lasers.

At Civan Lasers , innovation drives us to continuously push the boundaries of what’s possible in laser welding. Last year, we demonstrated the ability to weld 20mm thick SS 316  with exceptional mechanical properties , setting a new industry standard. Now, as we launch into 2025, our Application Lab Team  has reached an exciting milestone: successfully welding 30mm thick SS 316  in a single pass  using our Dynamic Beam Laser (DBL)  technology. Why This Matters for Industry This breakthrough is a game-changer for industries requiring thick-section welding, such as pressure vessel manufacturing , and energy infrastructure : Efficiency Gains : Faster welding speeds and single-pass capability reduce production times. In some cases, reducing process that take days into less than an Hour! Cost Savings : Lower energy consumption and reduced reliance on consumables result in significant savings. Unmatched Reliability : Superior mechanical properties and reduced defects ensure consistent, high-quality results for critical applications. Cross sections of SS 316LN 30mm Pushing the Limits: The 30mm Breakthrough This milestone was achieved using a 28kW DBL , operating with 23kW of power  and a travel speed of 22 mm/sec . The weld utilized a shape sequence of two beam shapes , dynamically switching between them every 10ms . This advanced method, previously proven effective for thick sections of mild steel, optimizes molten material flow, significantly reducing solidification cracks and porosity . Shape sequence of Single Point & U shape Mechanical Testing of 20mm Welds Mechanical testing of 20mm thick SS 316 welds demonstrated exceptional results, validating the superior quality achieved with Dynamic Beam Laser (DBL) technology. Tensile tests confirmed that the welds not only met but exceeded industry standards for SS 316, with achieving an ultimate tensile strength (UTS) of 660 MPa and 590 MPa, both surpassing the 490 MPa standard (AWS D1.6-2017). Bending tests further highlighted the weld's ductility and structural integrity, with both specimens passing—Side Bend with no critical defects and Side Bend 2 exhibiting minimal defect sizes (0.87 mm, 0.31 mm, 0.39 mm, and 3.45 mm at the corner). These results underscore the reliability and precision of DBL technology in delivering high-quality welds for demanding applications. SS 316 20mm cross section Future Plans: Pushing Thickness Limits Our work is far from over. The next steps for Civan Lasers include: Maximizing Thickness for the 28kW Laser : Continuing to refine and test the capabilities of the current DBL system for thicker sections. Advancing with the 42kW Laser : Developing and testing a higher-power laser system to push the limits of single-pass welding for even greater thicknesses.

The Dynamic Beam Shaping for High-Power Laser Welding workshop, held at WMG, University of Warwick, on January 28, 2025, officially launched the Lasers4MaaS project, a pioneering initiative under the European Union’s HORIZON Europe program. Gathering leading experts, researchers, and industry professionals, the event highlighted breakthroughs in dynamic beam shaping technology and digital technologies, paving the way for next-generation manufacturing solutions. The Lasers4MaaS (Lasers-as-a-Service) project  is designed to accelerate the adoption of dynamic beam shaping in smart, decentralized, and sustainable manufacturing. By leveraging Dynamic Beam Lasers, the initiative aims to transform industrial laser applications, improving efficiency, precision, and adaptability across multiple sectors, including automotive, aerospace, food packaging and renewable energy. As the kickoff event for Lasers4MaaS, this workshop set the foundation for collaborative research, industry engagement, and technological innovation in the field of high-power laser welding. Opening Session: Dynamic Beam Shaping for High-Power Laser Welding Pasquale Franciosa, Head of the Laser Beam Welding Group at WMG and Lasers4MaaS’s coordinator, welcomes attendees to the kickoff workshop of the Lasers4MaaS project at the University of Warwick. Key Presentations and Insights The event, chaired by Pasquale Franciosa (Lasers4MaaS’s coordinator at WMG), featured a lineup of industry experts and researchers , presenting cutting-edge advancements in laser beam shaping, AI integration, and real-world applications : Simon Webb (WMG HVM Catapult):   Supporting UK Advanced Manufacturing  – Exploring the role of laser technology in enhancing UK manufacturing capabilities. Mark Thompson (Photonics Express):   UK Laser Welding Market  – Insights into market trends, technological advancements, and industry growth. Ruben Cesana (Civan Lasers):   Overview of Civan Lasers and Dynamic Beam Shaping  – Presenting next-generation dynamic beam lasers  and their impact on high-precision industrial applications . Volkher Onuseit (IFSW):   Potentials of Beam Shaping Strategies and Machine Learning in Laser Welding  – Highlighting how AI and machine learning optimize laser welding for superior quality and efficiency . Aleksey Kovalevsky (Israel Institute of Metals):   Laser Welding with Dynamic Beam Shape Technology – Case Studies on Aluminium Alloys  – Demonstrating the advantages of dynamic beam shaping for complex welding applications . Simone Peli (Castellini):   Welding of Thick Sections with Pure Dynamic Beam Laser  – Showcasing deep penetration welding  techniques using high-power dynamic beam control . Domenico Stocchi (ECOR International):   Research in Welding and Digital Technologies for Product Diversification  – Discussing digital transformation in laser welding  and its implications for manufacturing efficiency . Innovations in Deep Penetration Welding with Dynamic Beam Control Simone Peli from Castellini presents advancements in welding thick sections using pure dynamic beam laser technology, highlighting high-power beam control for deep penetration welding. Live Demonstrations and Hands-On Learning A highlight of the workshop was the live demonstration of the dynamic beam laser, showcasing its real-time beam shaping capabilities. Attendees also participated in a guided tour of the new Advanced Laser Welding with Dynamic Beam Shaping Lab at WMG - the first of its kind in the UK. Live Demonstration of Civan Lasers’ Dynamic Beam Technology Attendees observe a hands-on demonstration of Civan’s OPA6 dynamic beam laser, showcasing real-time beam shaping capabilities for industrial applications. Looking Ahead The Lasers4MaaS project aims to bridge the gap between research and industrial adoption, ensuring that these innovations translate into tangible benefits for manufacturers worldwide. The Lasers4MaaS initiative will continue to foster collaboration between industry leaders, research institutions, and technology developers, driving forward a new era of smart, data-driven laser manufacturing. This kickoff workshop has set a strong foundation for ongoing research, industrial partnerships, and future breakthroughs in high-power laser processing.

Introduction   Addressing Challenges in Metal Additive Manufacturing Laser-based additive manufacturing (AM) technologies produce components of varying sizes, from millimeters (PBF-LB/M) to meters (DED-LB/M). Regardless of scale, the local temperature distribution and melt-pool dynamics significantly impact the mechanical properties of the final part. Unfavorable temperature distributions lead to process instabilities, manifesting in issues like melt ejection, spatter, and defects such as delamination and porosity. Key issues include:   Inadequate Control of Mechanical Properties An inappropriate energy input causes defects such as lack of fusion or porosity affecting not only the density but also the microstructure and therefore the variability of mechanical properties of the final part.  Necessity of Post-Processing Time-consuming post-processing operations are necessary to improve dimensional and surface quality (e.g. surface roughness) of the final part. High cost per part due to low productivity Despite the ability to manufacture complex part geometries the costs per part are high due to limited process speeds. Limited Material Portfolio The portfolio of printable metal alloys is limited due to inherent material failure such as cracking causes by inappropriate thermal conditions during the printing job. The root cause of these challenges lies in the steep thermal gradients and high cooling rates associated with traditional laser material processes. The inability to dynamically and precisely shape the laser energy input in both time and space, leaves manufacturers constrained in their ability to meet diverse material and design requirements. This whitepaper introduces dynamic beam shaping to additive manufacturing applications and demonstrates the potential of coherent beam combining to transform the industry. Figure 1. Cross-section of a single-track weld seam highlighting the presence of porosity and cracking caused by an inappropriate energy input. Control of energy input in space and time required to minimize process-related defects (e.g. lack of fusion, porosity, internal stresses) and gain control of the process outcome (e.g. microstructure, surface roughness). Dynamic Beam Shaping for Superior Results Civan’s Dynamic Beam Laser (DBL) technology offers transformative capabilities through dynamic beam shaping, enabling real-time modulation of the laser energy distribution. Two key applications where DBL delivers significant advantages in laser-based additive manufacturing are demonstrated in the following: PBF-LB/M Increase in Productivity with DBL In single track experiments with light-weight titanium alloy Ti6Al4V, the influence of different laser beam shapes on the weld seam geometry in PBF-LB/M was investigated.. The experiments were performed under constant process conditions  employing a laser power of 1000 W, a scan velocity of 1 m/s and a powder layer thickness of 50 µm. A ring-shaped beam profile and a spiral-shaped beam profile were compared to a standard Gaussian beam profile. The results show a significant improvement in weld seam width for the advanced beam shapes as visualized in Fig. 2: The ring-shaped beam profile increased the weld seam width by 23% compared to the standard Gaussian beam. The spiral beam shape achieved an even greater increase of the weld seam width by 134% compared to the standard Gaussian beam. Why does this matter? A wider weld seam allows the use of a higher hatch distance between consecutive weld tracks during the printing process. This reduces the number of tracks required to cover the same area, leading to (1) faster printing times and consequently (2) an increase in productivity. Further, by dynamically switching between beam shapes, such as ring or spiral intensity profiles, within a millisecond range, the technology additionally allows for flexible adjustment of the weld seam geometry during the printing process. This is of high relevance for the printability of parts that combine small, precise structures with large, expansive areas.  This real-time adaptability ensures optimal weld seam performance based on the part's geometrical conditions. Figure 2. Resulting weld seam morphology of single-track experiments with Ti6Al4V powder for three different beam shapes (P = 1000 W, v = 1 m/s). Using the “spiral” beam profile increases the weld seam width by 134 % in comparison to the standard “Gaussian” beam profile. DED-LB/M: Control of Melt Pool Geometry with DBL Unlike PBF-LB/M, which relies on melting predeposited powder layers, DED-LB/M involves the direct deposition of powder or wire material into the molten pool to generate a volumetric build-up. To understand how dynamic beam shaping influences the DED-LB/M-process, the performance of two beam shapes – snowflake and hourglass –  were compared. Whereas the snowflake beam shape resembles a static energy input approach, the use of the hourglass beam shape relies on the dynamic change of the energy input between the leading and trailing edge of the melt pool. The experiments were performed under constant process conditions using a laser power of 500 W, a feed rate of 400 mm/min and a powder mass flow of 3 g/min of hot working steel powder AlSlH11. This highlights the effectiveness of dynamic beam shaping in enhancing productivity by allowing precise control over melt pool geometry in DED-LB/M. Figure 3. Overview of melt pool geometry (a,d), surface appearance (b,c), and cross-section analysis (e,f) generated with a snowflake (left) and dynamically operating hourglass (right) beam shape by means of DED-LB/M. Potential of DBL for Metal AM Summarizing the first results in the context of additive manufacturing, the following potentials of DBL can be derived: Enhancing productivity: Combining high-speed production capabilities by adapting the beam profile to match part geometry, enabling higher feed rates. Reducing post-processing time. Steering the unit cell of additive manufacturing:: Microstructure control : Adjustment of microstructural  and resulting  mechanical properties through adaption of local cooling rates. Enhancing printability of hard-to-print materials : For example, additive manufacturing of high-strength materials like nickel-based superalloys while minimizing the risk of cracking by influencing the solidification process. Unlocking New Possibilities in Metal AM DBL technology represents a paradigm shift in metal additive manufacturing. By enabling real-time dynamic beam shaping, this innovation addresses longstanding challenges in microstructure control, part quality, and productivity. Investing in DBL lasers empowers manufacturers to push the boundaries of design and material performance, ensuring a competitive edge in a rapidly evolving industry. With its adaptability and precision, this technology is poised to redefine the future of additive manufacturing.

Civan Lasers is proud to announce that Mechanical Engineering Professor Lianyi Chen from the University of Wisconsin-Madison has become the first researcher to acquire a Dynamic Beam Laser (DBL) for Laser Powder Bed Fusion (LPBF) additive manufacturing. Prof. Chen, a renowned expert in utilizing beam shaping for LPBF, aims to leverage the unique capabilities of this laser to advance additive manufacturing technologies.   Dynamic Beam Lasers, developed by Civan, enable the generation of arbitrary beam shapes, a breakthrough that inspired Prof. Chen’s decision to integrate the DBL into his lab’s research.   Prof. Chen’s lab plans to integrate the DBL into a custom-built system featuring advanced sensors and closed-loop control. This setup will optimize process parameters in real-time, aiming to overcome defects and push the boundaries of what is possible in LPBF.   “Civan Lasers has traditionally focused on welding applications, but we are thrilled to see our technology being explored for LPBF by such a distinguished researcher,” said Ami Spira, General Manager of Civan Lasers Inc. “We are confident that Prof. Chen’s expertise and innovative approach will set a precedent for the entire LPBF community.” Illustration of using beam shape in an LPBF process

Additive manufacturing continues to redefine the boundaries of modern engineering, enabling the creation of intricate geometries and customized components with unmatched precision. A recent trial conducted by the Welding and Laser Group at the Technion – Israel Institute of Technology , one of the first research groups worldwide to utilize dynamic beam laser technology for Directed Energy Deposition (DED) with wire, has demonstrated the immense potential of this approach. The trial showcased the fabrication of a complex 8 cm tall tube using magnesium AZ-31 alloy, a material known for its lightweight properties and excellent strength-to-weight ratio. Leveraging dynamic beam shaping technology, the team produced a component with a refined and homogeneous dendritic structure—a feat that exemplifies the precision and versatility of this advanced laser technology. In just a short time, the component was fabricated with consistent quality throughout its structure, highlighting dynamic beam shaping's ability to optimize energy distribution, reduce defects, and enhance material properties. Building stages of the 8cm Az-31 structure Images of the structure before and after post-processing Microstructure analysis The Role of the Welding and Laser Group at the Technion This remarkable trial was conducted by the Welding and Laser Group at the Technion , a leading research group specializing in advanced welding, laser processing, and additive manufacturing technologies. Their expertise in integrating innovative techniques with cutting-edge materials positions them at the forefront of research in these fields. The group focuses on solving real-world challenges across various industries, leveraging interdisciplinary approaches to develop groundbreaking solutions in manufacturing. To learn more about their work and projects, visit their official page: Welding and Laser Group at the Technion .   Unlocking New Possibilities for DED Wire Processes Dynamic beam shaping technology plays a pivotal role in unlocking the potential of magnesium alloys like AZ-31. Unlike static beams, dynamic beam shaping allows real-time modulation of the laser’s properties to suit the material's specific needs. This approach minimizes common issues such as porosity and cracking, which are prevalent in traditional manufacturing processes, and results in superior mechanical and structural properties. This effort by the Technion demonstrates the potential for expanding DED wire processes. The team plans to further explore how different power distributions enabled by dynamic beam shaping can lead to additional breakthroughs in additive manufacturing. Future investigations aim to develop new applications across industries.   Contact the Technion Welding and Laser Group To learn more about this groundbreaking research or explore potential collaborations, contact the Welding and Laser Group at the Technion  via their official website  or reach out directly to their team of experts. The group welcomes inquiries about their work and the exciting future of dynamic beam shaping technology in manufacturing. Laser Cell at Technion and beam shape used for the AZ-31 structure

Civan Lasers proudly announces the opening of two advanced demonstration labs in the United States, strategically located at AMET in Rexburg, Idaho, and Photon Automation  in Detroit, Michigan. These new facilities represent a major step forward in providing North American customers with greater accessibility to Civan’s innovative Dynamic Beam Laser technology. At both locations, clients can experience the transformative capabilities of Dynamic Beam Lasers, designed to redefine laser welding processes. These labs offer hands-on demonstrations and tailored process development, empowering customers to explore the full potential of this groundbreaking technology. Strengthening Civan’s Presence in North America The demonstration labs are integral to Civan Lasers' go-to-market strategy for the North American market. With a robust service and sales infrastructure already in place, the labs mark the final phase of establishing local operations. This expansion enables Civan to offer comprehensive solutions and support, ensuring that customers can seamlessly integrate Dynamic Beam Lasers into their operations. The AMET Partnership in Rexburg, Idaho Civan’s partnership with AMET, a renowned expert in welding machinery, allows the Rexburg facility to offer customers turnkey welding solutions powered by Dynamic Beam Lasers. Visitors to this location can develop customized welding processes and explore how this technology can address their specific challenges. Demo Lab at AMET Photon Automation in Detroit, Michigan In Detroit, Photon Automation—a leader in laser welding solutions with deep expertise in the automotive and electrification - hosts Civan’s second demonstration lab. This facility is strategically positioned to serve Michigan’s vast industrial base, offering customers the opportunity to explore advanced laser applications with the support of Photon Automation’s extensive experience and resources. Demo lab at Photon Automation Revolutionizing Welding with Dynamic Beam Lasers Civan’s Dynamic Beam Laser technology provides unmatched control over beam shaping, enabling innovative solutions for challenging materials and thick sections. Applications include welding thick copper components, thick stainless steel welds, and large wind tower sections—areas where traditional welding methods are slow and complex.   Comprehensive Turnkey Solutions These demonstration labs go beyond showcasing cutting-edge laser technology. Through collaborations with AMET and Photon Automation, customers gain access to a seamless pathway from process development to full-scale production. The turnkey systems offered at both locations ensure that clients can confidently transition their projects from concept to completion. Civan Lasers’ new demonstration labs underscore the company’s commitment to advancing laser innovation and delivering transformative solutions to the North American market.

Fraunhofer IOSB Acquires 120 kW Dynamic Beam Laser — One of the Most Advanced Lasers in the World Due to Its High Beam Quality — for Research. Civan Lasers is thrilled to announce it has received a purchase order for a groundbreaking 120 kW single-mode dynamic beam laser from Fraunhofer IOSB. This acquisition marks a significant milestone, as the laser is the highest-power single-mode laser currently available on the market. The 120 kW laser was first delivered in 2021 and won the 2022 Laser World of Photonics Innovation Award . The uniqueness of this laser lies not only in its power level but also in its high beam quality and dynamic beam features. These capabilities allow users to tailor the beam profile and power distribution during operation, providing unmatched flexibility and precision in various applications. Designed for industrial use, the laser is compact, with dimensions of just 2 x 2 x 1 m, making it easy to transport and easy to install in different sites with a variety of machine configurations and interfaces. This versatility ensures it can be effectively utilized for a wide range of applications. Since its first deployment in 2021, the laser has been used in welding and other industrial processes. Civan has deployed many high-power lasers for different applications, with power levels ranging from 14 kW to 120 kW. This purchase will enable Fraunhofer IOSB to lead in the research of high-power lasers, opening up new opportunities for exploring innovative applications. The advanced features of this laser, including its high beam quality and dynamic beam shaping capabilities, will provide unparalleled flexibility and precision in research efforts.

Civan Lasers is proud to introduce its new welding head, designed exclusively for our Dynamic Beam Laser. This new product offers a standard solution for welding applications, eliminating the need for additional complex optic delivery systems. Why Choose New Welding Head? The primary reason for developing this welding head is to provide a standardized, hassle-free solution specifically for Civan's Dynamic Beam Laser. By offering a robust and versatile design, it simplifies the process, ensuring that users do not need to invest in or manage complex optical delivery setups. This welding head is engineered to meet the high demands of manufacturing environment. Key Features of Civan's Welding Head Optics Protection : Our welding head ensures the protection of optics used in welding applications. Its sealed design prevents damage from spatter and fumes, extending the lifespan of the optics and maintaining consistent performance. Easy Installation : The welding head is engineered for simplicity, enabling quick and straightforward installation of the Dynamic Beam Laser. This design minimizes the need for optical alignment. Ease of change Focusing Lens : The welding head offers flexibility in focal length, allowing for switching between different focusing lenses to change focal distance and beam diameters with the same lasers. Compact and Robust Design : With dimensions of 736x 445x 344mm and a weight of up to  80Kg (including the galvo scanner), the welding head is both compact and robust. It integrates seamlessly into existing setups without requiring significant modifications. Integrated Coaxial Camera : The built-in coaxial camera enhances monitoring and control, allowing operators to oversee the process in real-time and make necessary adjustments promptly. Optional Sensor Ports : The welding head can come with optional ports equipped with a beam splitter up to custom demand, facilitating the integration of additional sensors. This feature enhances its versatility and functionality, accommodating a wide range of applications. Easy Maintenance : The design includes an easily replaceable protective window, ensuring minimal maintenance efforts and reducing operational interruptions. Thermal Shift Correction : Real time Active correction of thermal lensing in optics maintains precision and accuracy, even during prolonged use, ensuring consistent quality of the welds or AM outputs. Collaboration with SmartMove Civan Lasers and SmartMove have an ongoing collaboration for integrating dynamic beam lasers with their galvo scanner. SmartMove is able to offer the SH30G-ME-LD scanner that can withstand up to 14kW! In addition, they provide a state-of-the-art controller with high accuracy. This collaboration between the companies offers unique features that don't exist in any other solution. The first is the beam orientation capability, and the second is the autofocus correction, which eliminates the need for an F-theta lens and mechanical movement of the focusing lens. The integration of SmartMove technology enhances the functionality and efficiency of Civan's welding head, offering  an invaluable tool for manufacturing processes.