Civan's Dynamic Beam Laser technology welds battery cooling plates at feed rates of 30 m/min. When it comes to temperature extremes, electric vehicle (EV) batteries are a lot like people. EV batteries perform best in the same sort of temperature ranges as humans do. EV thermal management systems maximize battery performance and extend its life. Cooling plates in an EV thermal management system allow liquid coolant to remove heat from the battery. Click to read more about current challenges in the manufacturing of EV battery coolers >

Civan's dynamic beam laser welds 70 mm thick in a single pass. The Fabricator: "Civan's Dynamic Beam Laser has led to some eyebrow-raising accomplishments, the most recent one announced on Feb. 9, when the company said it completed a single-pass weld that’s 70 mm deep, accomplished at atmospheric pressure—no vacuum required." Read more about the technology at The Fabricator > This concept illustration shows a dynamic beam laser welding 70-mm-thick plate in a single pass.

Introduction In the automotive industry a wide range of different materials have to be joined with a direct focus on productivity, repeatability and robustness. Laser Beam Welding offers high process speeds with minimal changes to the base material properties. Conventional laser systems reach their limits by processing modern alloys, challenging materials or material combinations that can be found in the automotive industry. Automotive parts use materials like aluminum, copper, and mixed alloys. Each material behaves differently under heat. For example, aluminum die-cast housings are common units for enclosures of electrical components. Conventional laser beam welding can be challenging due to the dissolved hydrogen in the base material, which tends to cause porosity in the weld seam. Copper is highly reflective for lasers typically used in the NIR-regime. This makes copper very difficult to weld with conventional systems. Welding dissimilar aluminum and copper joints causes the formation of intermetallic phases, reducing the strength and the electrical conductivity of the joint. The Dynamic Beam Laser (DBL) of Civan Lasers offers a universal tool to counteract these challenges that occur in the automotive industry and the electro-mobility sector. Dynamic Beam Laser offers an unique technology to shift the laser focus within the focal plane in the MHz region. This contributes to a precise control of the heat generation by creating individual Dynamic Beam Shapes, Fig. 1. Fig.1: Dynamic Beam Laser (DBL) (left) and Dynamic Beam Shaping (right) Dynamic Beam Shaping for universal heat input alignment Aluminum Die-Cast Aluminum die-casting is a cost-effective method for producing compressor components, heat exchanger and enclosures. Dissolved hydrogen in the base material leads to high porosity in the weld seam. The result is low static and cyclic strength, which leads to inadequate results in fatigue or burst tests. With the DBL technology from Civan Lasers, a Dynamic Spiral can be used to directly address the challenges of aluminum die-cast alloys and improve the quality of the joint, Fig.2. Fig.2: Welding leak tight Al Die-Cast Housings (AlSi10MgFe) with Dynamic Spiral Shifting the laser intensity to form a spiral within the 5–40 kHz frequency region will cause the melt pool to follow the temperature gradient of the beam shape. As a result, the degassing of the molten material is supported by forming a stabilized keyhole. The hydrogen content can easily escape the molten pool and prevent the formation of pore clusters. Additionally, the same Beam Shape can be used for a polishing of the weld seam that can both lower the pore content and increase the surface quality. The frequency of the Beam Shape is increased to 500 kHz. In this frequency region, the melt pool will react quasi static without following the temperature gradient. This supports the formation of a sealed surface which enhances the leak tightness. In order to exploit the advantages of both strategies, the welding process can be divided into two steps. In the first pass, a low beam shape frequency promotes a high weld depth. A second pass with increased beam shape frequency is used to polish the weld. This can be implemented directly in-line, enabling feed rates of up to 150 mm/s. Compared to friction stir welding, process times can be reduced by a factor of more than 10. Aluminum Wrought Alloy Battery cooling plates are used to stabilize battery temperature and keep performance consistent in electric vehicles. Today, these components are mostly joined using brazing. While brazing is well understood, it is expensive and has limitations in cycle time and process control. Laser welding offers a cleaner alternative, but maintaining quality at high speed is still a challenge. A typical cooling plate can require more than 20 meters of continuous weld, where even a single leak is not acceptable. For the processing of wrought aluminum alloys, high process speeds of up to 500 mm/s are targeted, which allow leak tight welding of plate material (e.g. overlap joint – 1 mm to 2 mm). A beam shape with a special intensity distribution is used to meet these requirements, Fig. 3. Fig.3: Welding of Cooler Components (AA 5754) with up to 500 mm/s feed rate Combining high central laser intensity with a surrounding ring of lower intensity enables high welding depths at high process speeds. The beam shape used is directional and rotates in the direction of the velocity vector during the process. This beam shape can be aligned automatically and applied to any geometry using scanner optics (e.g. direct import of welding paths from CAD models). The welded cooler component was fully leak-tight at 2 atm overpressure. Special beam shapes can also be used to manufacture similar components for higher-strength alloys (AA 6000 and 7000 series). Due to their alloy composition, these material systems tend to form hot cracks. By specifically adjusting the heat input, the solidification intervals within the welding process can be directly influenced. This allows for a significant reduction in hot crack sensitivity. Pure Copper & Dissimilar Cu – Al Joints Thick copper bus bars are used in fast charging systems to carry very high currents with minimal electrical losses. As charging speeds increase, the demand for higher conductivity and thermal stability grows, which drives the use of thicker copper sections. Today, joining these components is challenging due to copper’s high reflectivity and thermal conductivity. Traditional methods can struggle with consistency and heat control. Laser welding offers a precise solution, but achieving stable, deep welds in thick copper while maintaining quality remains a key challenge. Joining electrical contacts are a main topic in the electro-mobility sector. In addition to conventional copper or aluminum conductors, there is a growing demand for dissimilar Cu-Al joints. Copper has a high thermal conductivity and reflects a high percentage of laser power in its solid state. Combining different beam shapes into sequences offers another option for direct process control, Fig.4. Fig.4: Welding up to 6 mm pure Copper with Dynamic Beam Shape Sequence An alternating arrow shape combines preheating of the material at low laser intensity in the leading edge with a high penetration depth due to higher intensity in the center of the beam shape. The surface of the material initially melted due to the preheating of the arrowhead. In the molten state, copper has a highly increased laser absorption, which provides a more stable process with higher penetration depth and better surface quality. Fig.5: Welding up to 3 mm Dissimilar Cu – Al Joints with Double Sided Spiral Due to the formation of intermetallic compounds (IMCs), dissimilar Cu-Al joints often exhibit low strength and high electrical resistivity. Civan's beam shaping technology enables both materials to be heated precisely, minimising the formation of IMCs. This makes it possible to produce high-quality electrical contacts in the form of sheets, wires or strands. Civan’s Dynamic Beam Laser – The Key Solution for every Material Dynamic Beam Laser (DBL) enables new capabilities in automotive and e-mobility manufacturing. It allows better control of heat input, which improves weld quality and makes laser welding viable in applications that were not possible before. At the same time, it supports higher processing speeds, helping reduce cycle time and cost. In many cases, both benefits come together. DBL improves stability while increasing throughput, making laser welding both technically feasible and economically attractive for next-generation automotive production.

Modern production lines aim to achieve zero defects to avoid wasting high value goods. Therefore, sensors are required to ensure correct alignment and positioning of welding components. Misalignment and rotation can be compensated by adjusting the laser beam path. Sensors are not only needed prior to the welding process but also during the process itself to monitor and respond to irregularities and potential defects. Depending on the workpiece, sensor type, and defect, the process can be adapted in real time to ensure high-quality welds, or the workpiece can be marked for further inspection and rework. The Right Sensor for the Right Application Workpiece Alignment High-precision positioning of workpieces can be time-consuming and expensive. Modern camera systems and computer vision algorithms can help reduce this cost in serial production lines. Workpieces can be positioned within a defined tolerance and fixed using flexible clamps. The camera system detects characteristic geometries of the workpiece. Points derived from these geometries are compared to a reference, and the weld trajectories are adjusted accordingly. Depending on the system, the camera can be placed coaxially or off-axis to the laser beam path, providing flexibility in implementation.    Seam Tracking Sensors can be used not only to align complete workpieces but also to track individual weld seams or edges and compensate for manufacturing tolerances and deviations. For this purpose, line sensors and tactile sensors can be used. These sensors can be easily integrated when using a robot to move along the planned trajectory. In both cases, the sensor observes the area in front of the laser beam, detects the correct weld path, and provides feedback to an offset-compensating linear axis or laser scanner. In the case of a wider gap in a butt weld or a lift-off in a lap joint configuration, the laser process can be adjusted accordingly, for example by increasing wobble amplitude or laser power. Weld Monitoring One option to monitor the welding process is photo diode-based devices. These measure light emissions from the welding zone across different spectral ranges. The number of spectral ranges varies depending on the manufacturer, but in principle, welding defects can be detected by comparing the photodiode signal of the current weld to defect-free reference welds. Figure 1 shows an example of a recorded welding process. Each color in the graph represents a different spectral range. In the first section, the weld performs as expected. The rising signal amplitude indicates increasing heat accumulation in the workpiece. In the second section, melt is expelled from the welding zone and the signal rises until saturation. This may be caused by evaporation of contamination, entrapped gases, or full penetration of the laser beam with material evaporation on the backside. Afterwards, the signal becomes irregular with intermittent spikes, indicating an unstable collapsing keyhole. In the final section, the process stabilizes again. Example for a photo diode signal recording during copper welding By analyzing this information, the process can be adjusted to prevent such defects, or workpieces can be selected for further inspection, reducing the number of required test samples. Additionally, if multiple weld signals deviate from the reference, this may indicate a systematic issue, such as contamination of the protective window in the laser optics. A trained operator can respond accordingly, reducing costly failures and machine downtime. Implementation of Sensors into a Civan Dynamic Beam Laser System  The Civan Dynamic Beam Shaping Laser is very flexible in sensor integration and system integrators can easily mix and match with industry proven sensor solutions. Cameras for workpiece alignment can be installed stationery and communicate with the beam steering device, like galvo scanners or robots. In applications where the optical head is mounted on a robot, the camera can also be mounted on the robot to increase flexibility. In scanner-based welding, a coaxial camera can capture the region of interest prior to welding. Seam tracking devices, such as line sensors, can be installed on robots or linear axes to measure ahead of the welding zone. Photodiode sensors are best placed coaxially to the laser beam so that the welding zone is continuously monitored. A schematic illustration of a possible integration into the optical head of a Civan Dynamic Beam Laser is shown in Figure 2. Schematic illustration of the integration of a photo diode sensor into the optical head of a Civan Dynamic Beam Laser The standard port of the coaxial camera can be adapted with a suitable beam splitter which reflects and transmits light the relevant wavelengths. Examples of an actual setup using a 4D.TWO and Laser Weld Master sensor are shown in Figure 3 and Figure 4, respectively. Figure 5 shows the integration of a Plasmo to a Civan Dynamic Beam Laser. Here, off-axial fibers which are connected to photo diodes are pointing at the workpiece together with a co-axial fiber, which is also connected to the photo diodes. Overall, sensors are essential tools in industrial laser welding applications, enabling easier workpiece positioning and consistent weld quality. Civan Dynamic Beam Lasers support the integration of the most relevant sensor types, allowing for adaptive and controlled welding processes. Civan optical head with connected 4D.TWO sensor Civan optical head with connected Laser Weld Master sensor; photo Pasquale Franciosa (University of Warwick) Integration of a Plasmo photo diode sensor system to a Civan Laser with scanner optic

Laser welding of thick sections differs fundamentally from conventional arc-welding processes in both thermal behavior and defect-formation mechanisms. The process is characterized by significantly lower heat input per unit length and much higher energy density, producing a narrow heat-affected zone, reduced residual distortion, and diminished need for post-weld correction. However, the highly concentrated and dynamic laser–material interaction introduces additional physical challenges—particularly related to keyhole stability and molten-pool force balance—that must be precisely controlled to achieve defect-free welds in thick materials. In this context, pure laser welding  denotes root welding performed solely by a laser beam, with or without filler-wire addition. Successful implementation therefore requires careful optimization of component design, joint configuration, and process control. This article presents the key considerations and technological capabilities associated with pure laser welding of thick sections. 1.     Joint type and Design Considerations A wide range of joint geometries traditionally associated with arc welding can also be realized using laser welding, while benefiting from the process’s deep penetration capability and localized thermal input. In square-groove butt joints , where no bevel is required, sufficient laser power and beam stability enable single-pass full penetration in thick materials. Demonstrations using high-power dynamic beam lasers have shown single-pass full penetration in approximately 35 mm-thick mild steel, including procedure qualification according to international standards. For even greater thickness, double-sided laser welding may be applied. T-joints  may be welded autogenously or with filler-wire addition, and from one or both sides. Autogenous laser welding minimizes heat input and distortion, whereas filler wire enables reinforcement formation and metallurgical tailoring. Overlap joints   (lap joint in AWS terminology)  are particularly compatible with laser processing because the beam can penetrate multiple stacked plates, achieving penetration depths exceeding 25 mm, depending on material and process conditions. Overlap welds may be designed for full penetration or partial penetration. Because the load-bearing capacity of overlap joints is governed primarily by the interface width, this region can be increased through multiple welding passes, increased spot size or by tailored beam-shape parameters. Figure 1: Cross-sectional macrographs of representative laser-welded configurations: (a) 25 mm mild steel butt joint; (b) 45 mm mild steel double-sided butt weld; (c) 4 mm Al 5083 T-joint without filler wire; (d) 8 mm mild steel T-joint with filler wire; and (e–g) mild steel lap (overlap) joints exhibiting penetration depths from 7 mm to 25 mm. 2.     Mechanical Integrity and Metallurgical Considerations Laser welding is characterized by significantly higher cooling rates than arc welding, yet welds in stainless steel, mild steel, and aluminum alloys can still meet international qualification standards such as ISO 15614-11. The highly localized thermal cycle limits grain coarsening in the heat-affected zone, while rapid solidification promotes fine microstructures that contribute to strength. When additional metallurgical control or reinforcement is required, filler wire may be introduced within the same laser pass to enable uniform penetration, alloy modification, and geometry correction. The relatively high travel speeds typical of laser welding further support weld quality when properly optimized. Faster welding shortens the molten-pool lifetime and reduces heat input, helping to suppress keyhole overexpansion, vapor entrapment, porosity formation, and shrinkage-induced cracking. At the same time, appropriate speed contributes to a stable balance between recoil pressure, surface tension, and hydrostatic forces within the keyhole, enabling consistent deep-penetration welding. These advantages, however, exist only within an optimal process window, since excessively high speeds may instead lead to lack of penetration or humping instabilities. Table 1: Mechanical test results for representative laser-welded joints in S355J0, 316L stainless steel, and aluminum 5083, demonstrating compliance with international qualification standards (ISO 15614-11 and AWS D1.6). The measured values confirm the capability of laser welding to achieve high mechanical performance across different materials and thicknesses.    3.     Incompletely Filled Groove (Face Underfill) During thick-section laser welding, an incompletely filled groove may occur as a surface imperfection resulting from the combined effects of solidification shrinkage, melt-pool flow, hydrostatic pressure, and surface-tension-driven (Marangoni) convection within the large molten volume characteristic of deep-penetration welding. These mechanisms can prevent sufficient liquid metal from remaining at the weld face during final solidification, producing a depression in the reinforcement profile. Partial mitigation may be achieved by increasing travel speed to reduce heat input and molten-pool volume. In addition, welding in a vertical position may in certain configurations assist molten-metal redistribution toward the weld face, thereby reducing the tendency for surface depression. However, when available laser power is limited, full penetration cannot be achieved, or beam shaping cannot adequately redistribute energy, additional corrective measures are required. Practical solutions include a secondary surface-filling pass—performed either by laser with filler wire or by GMAW—where added material compensates for shrinkage and restores the required surface geometry, or a single-pass laser weld with filler wire that prevents material deficiency from occurring. In some production environments, post-weld machining of the reinforcement is applied instead of filler addition, making minor surface depression acceptable within the manufacturing route. Regardless of the selected approach, effective control of an incompletely filled groove is essential for compliance with international weld-quality standards such as ISO 13919. Figure 2: Examples of incompletely filled groove mitigation strategies in thick-section laser welding: (a) cross-sectional macrograph of a 35 mm thick stainless steel weld exhibiting face underfill; (b) schematic illustration of post-weld machining (milling) of the top and bottom surfaces; (c) radiographic image of the machined 35 mm stainless steel weld meeting acceptance criteria; (d) cross-sectional macrograph of a 20 mm thick stainless steel joint welded in two passes—laser root pass followed by GMAW surface-filling pass to eliminate underfill; and (e) cross-sectional macrograph of a 15 mm thick mild steel joint welded in a single laser pass with filler wire, showing complete surface reinforcement without underfill. 4.     Welding Position, Beam Incidence, and Melt-Pool Stability Laser beams can be delivered to the workpiece at various incidence angles, enabling welding in all standard positions, including 1G (flat), 2G (horizontal), 3G (vertical), and 4G (overhead). Although positional accessibility is therefore not a fundamental limitation of laser welding, each welding orientation significantly influences keyhole stability, melt-pool geometry, and the relative effects of surface tension, recoil-pressure, hydrodynamic, and hydrostatic forces. Vertical and overhead welding positions introduce a destabilizing gravitational component along the direction of molten-metal flow, increasing melt-pool asymmetry, reducing effective surface-tension support, and raising the likelihood of droplet ejection, humping, or keyhole instability. As a result, the stable processing window becomes narrower and more sensitive to parameter variation, requiring enhanced keyhole stabilization and precise control of thermal distribution and melt-pool fluid flow. Dynamic beam-shaping technology provides this control by enabling dynamic beam shaping for redistribution of energy density and recoil pressure, thereby regulating melt-pool dimensions, temperature gradients, and flow behavior to restore the force balance necessary for stable deep-penetration welding—an effect that is particularly critical in thick-section applications where minor instabilities can rapidly evolve into significant weld defects.   Figure 3: Positional laser welding examples: (a) schematic illustration of the vertical welding position; (b) cross-sectional macrograph of a 35 mm thick mild steel weld produced in the vertical position; (c) photograph of the overhead welding setup; and (d) cross-sectional macrograph of a 25 mm thick mild steel weld produced in the overhead position, where partial penetration was specified as the requirement.   To conclude, Pure Laser Welding  of thick sections—particularly when enabled by dynamic beam-shaping control—significantly expands the practical design and manufacturing envelope compared with conventional arc-based processes. The combination of high energy density, rapid thermal cycles, and controllable keyhole–melt-pool dynamics enables welds with narrow heat-affected zones, low distortion, and mechanical performance consistent with international qualification standards. However, the process remains sensitive to force balance, heat input, and fluid-flow stability, especially in thick materials and positional welding, making precise control of travel speed, energy distribution, and reinforcement formation essential. When these factors are properly managed, pure laser welding becomes a robust, efficient, and industrially scalable solution for high-integrity thick-section fabrication across diverse materials, joint configurations, and welding positions.

Civan Lasers is launching DBL Gen III, the third generation of the Dynamic Beam Laser. This release marks a step forward. Gen III was designed from the ground up for industrial production. It is more reliable, smaller, and easier to integrate into real manufacturing environments where uptime matters and systems run around the clock. The DBL platform has evolved steadily over the years. In 2018, Civan built the first prototype to prove that coherent beam combining with dynamic beam shaping could work at high power. In 2020, DBL Gen I entered the field and was adopted by leading universities and research centers. Its role was clear. Enable fundamental research and explore what dynamic beams could do. In 2022, DBL Gen II became the first version adopted by industry. It moved the technology out of the lab and into production environments. Now, in 2026, DBL Gen III takes it a step forward. Evolution of DBL Technology: This image showcases the progression of Civan Lasers through three generations. DBL Gen III is offered in a wide range of power levels. The lineup includes 16 kW, 24 kW, 32 kW, 40 kW, and up to 120 kW. All models share the same core architecture and the same dynamic beam capabilities. This allows customers to scale power without changing the fundamental system design or process approach. One of the biggest changes in Gen III is system miniaturization. The laser system is significantly more compact than previous generations. This was achieved through a transition to new power supplies, a new compact optical head design, and an enhanced amplifier architecture. The smaller footprint makes the system easier to integrate into industrial cells, gantries, and robotic platforms, especially in space constrained production lines. System performance was also improved at both the hardware and software levels. Gen III delivers higher reliability and more stable dynamic beam behavior over long production runs. These improvements directly support continuous operation and consistent process results, even in demanding industrial conditions. A key contributor to reliability is the new power supply design. This new design improves system stability and reduces complexity. At the same time, it delivers a 60 to 80 percent reduction in electronic components. The laser head was completely redesigned for industrial durability. New lightweight materials were introduced, along with improved thermal management. The design actively prevents heating and damage to optical elements during high power operation. This leads to better performance stability and longer optical lifetime in production environments. The amplifier itself is now more compact and more powerful. Gen III delivers higher output power in the same physical size while reducing overall weight. This improves integration and handling while maintaining high performance. Reliability was a core design requirement throughout the amplifier redesign. DBL Gen III is built for production environments that cannot afford downtime. It supports nonstop operation, easier integration, higher uptime, and stable dynamic beam control at very high power. This generation is not an incremental update. It is the version designed to live on the factory floor. Learn more: https://www.civanlasers.com/products

The Challenge with Traditional Laser Welding Laser welding already brings speed, precision, and cleanliness compared to traditional welding. But conventional lasers still face limits that slow adoption in heavy manufacturing: Weld quality depends on tight tolerances. Access to complex joints is difficult. Multipass welding on thick sections adds time, cost, and distortion. These barriers often force manufacturers to rely on older processes or complex workarounds. Civan’s Dynamic Beam Laser (DBL) Civan’s DBL adds a new layer of control by shaping and steering the beam in real time. This makes it possible to weld parts and joints that conventional lasers struggle with, while cutting costs and improving consistency. An Overview of Dynamic Beam Laser Capabilities Six Core Advantages of DBL 1. Large Focal Plane DBL maintains high beam quality across a wide focal plane. Engineers can weld from farther away, making it easier to reach tight or difficult areas without special optics. The large focal plane enables remote welding, so the laser can reach any point within line of sight 2. Welding in 1G, 2G, and 3G Positions DBL adapts to the part instead of forcing the part to adapt to the laser. Welders can bring the laser to the workpiece, avoiding the need for manipulators or complex fixturing to rotate heavy sections into the flat (1G) position. Remote 3G welding of 35 mm thick steel from a distance of 1.5 meters 3. Overcoming Large and Varying Gaps Traditional lasers require perfect fit-up. DBL tolerates real-world conditions. Example: bridging a 2 mm gap in a 15 mm thick plate without loss of quality. With Dynamic Beam Shaping, the beam is tailored to fuse the joint walls rather than escape through the gap 4. Single-Pass Thick Section Welding DBL can weld up to 35 mm in mild steel in one pass. This removes the need for multipass processes that add time, introduce excess heat, and often require flipping the part. Single Pass welding of 35mm S355J0 5. Low Heat Input The concentrated, fast-moving beam minimizes heat dissipation into the material. Results: minimal distortion, smaller heat-affected zones, and less post-processing. Example: 16 mm stainless steel weld with minimal distortion 6. Easier Pre-Processing No beveling required. Straight walls from milling or even plasma cutting are sufficient, reducing preparation time and cost. Solving the Manufacturing Bottleneck Manufacturers face a shortage of skilled labor, growing demand, and pressure to reduce costs. DBL addresses this by delivering higher throughput, consistent quality, and easier integration into existing production lines — without relying on complex fixtures or extensive rework. Dynamic Beam Lasers remove the key barriers that held traditional laser welding back. With large focal planes, flexible welding positions, gap tolerance, and single-pass thick section capability, DBL enables welding and production engineers to simplify processes, cut costs, and expand capacity.

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.

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.

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 WeldingPasquale 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 ControlSimone 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.

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.

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