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.