Direct Laser Welding Design Guidelines

Download these guidelines.

What is Direct Laser Welding?


  • Direct laser welding applies laser energy to both components directly. The energy heats the weld surfaces. Then, the tooling presses the parts together.
  • The direct laser welding process is helpful in applications that require a clean, precise weld of non-transmissive materials.
Two red lasers hitting a machine
Direct Laser welding machine

Weld Joint Design

Weld joint design diagram


  • Include 0.5 – 1.0 mm of material overlap in the weld joint.
  • Design the weld rib width according to the specific application’s requirements, typically 0.5 – 3.0 mm.
  • Maintain at least a 0.25 mm gap between non-welded surfaces to prevent hard-stop condition.
  • Maintain at least 1.5 mm of clearance from internal part geometries to avoid interferences with the laser beam.
  • If concealing flash is required, make the flash trap large enough to contain the material displaced in the weld rib.

Part Design


  • For simple applications, minimize height changes to prevent the laser beam spot from being out of focus.
  • For large, complex applications, additional laser sources or optical tools may be used.
  • Built-in part alignment features are not necessary because tooling will align the components.
  • Components should include 0.5 – 1.0% carbon black for faster weld times.
  • Large parts can be welded with multiple laser emitters.

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