Scanner welding: Highly dynamic remote laser welding for industry

What is scanner welding?

Scanner welding is a highly dynamic remote laser welding process in which the laser beam is guided precisely and almost instantaneously over the workpiece using scanner optics. As a result, the process enables extremely high welding speeds, flexible beam guidance and efficient processing without mechanical movement of the optics for beam guidance.

Scanner welding enables highly productive manufacturing without non-productive times. Thanks to the dynamic beam deflection, the laser beam is moved between different welding positions in fractions of a second - completely without mechanical axis movement to position the beam. This principle forms the basis for "welding on the fly" and makes it possible to process even complex geometries with maximum speed and precision.

The process is based on the optical deflection of the laser beam via highly dynamic mirrors in the scanner head. These position the beam exactly where the energy is needed - quickly, precisely and reproducibly.

"Welding on the fly" describes a continuous process principle in which the movement of the gantry is combined with the dynamic beam deflection of the scanner optics. The laser no longer works step by step, but moves dynamically between the welding positions. While the optics move along the component, the laser beam is simultaneously guided over galvo mirrors. Points are not approached, but controlled directly - while the process is running. This enables a new form of processing: fast, flexible and precise at the same time. The energy is applied exactly where it is needed - without standstill, without additional positioning movements.

The result is a process that combines speed and control.

The high speed of scanner welding requires equally precise control. The position of the laser beam is digitally controlled and can be reproduced with high repeat accuracy. This means that even complex geometries can be implemented precisely. The energy is applied in a targeted manner - controlled, reproducible and stable. The result is a process that is not only fast, but also reliable.

As dynamics increase, so do the requirements for process control. As the laser beam switches between positions in fractions of a second, all relevant parameters must be continuously monitored and precisely adjusted. Data-based and AI-supported methods make it possible to evaluate process signals in real time and detect deviations at an early stage. On this basis, the process control can be adjusted immediately - not just downstream, but directly during welding.

The result is a system that not only works quickly, but also thinks for itself: it reacts to changes, stabilizes the process and ensures consistent results. The combination of dynamic beam guidance and intelligent evaluation thus forms the basis for modern, adaptive laser welding processes.

High welding speed and short cycle times
Scanner welding enables extremely short cycle times thanks to the highly dynamic beam deflection. Remote laser welding eliminates mechanical movements for beam positioning, minimizing non-productive times and significantly increasing productivity.

Flexible beam guidance without component movement
Optical beam deflection allows the laser beam to be guided flexibly over the workpiece. Remote laser welding enables processing without mechanical axis movement for beam guidance, thereby increasing efficiency and flexibility in production.

Low wear and high process stability
As no mechanical movements are required for beam guidance, scanner welding significantly reduces component wear. At the same time, the precise beam guidance ensures high process stability and consistent quality.

Advantages of remote laser welding compared to conventional laser welding
Remote laser welding offers decisive advantages over conventional processes. Non-contact processing eliminates the need for mechanical movements for beam positioning, which shortens cycle times and increases productivity. At the same time, the process enables flexible processing of complex geometries with high process stability.

Scanner welding is used in numerous industries, especially where many precise welded joints are required:

Scanner welding in automotive and body-in-white

Scanner welding is used in the automotive sector, especially for body-in-white applications. Remote laser welding enables high welding speeds and flexible beam guidance without component movement. This allows cycle times to be reduced and complex geometries to be joined efficiently.

Laser scanner welding for batteries and e-mobility

In e-mobility, scanner welding plays a central role in the production of battery housings and electrical components. The process enables precise, reproducible weld seams at high process speeds. Remote laser welding offers decisive advantages for aluminum in particular.

Use in series production and automated production

Scanner welding is ideal for highly automated production lines. Large quantities can be produced economically thanks to non-contact processing and fast beam deflection. At the same time, the high process stability ensures consistent quality in series production.

The technology is suitable wherever high speed, flexibility and reproducible quality are required.

Further information

Further information on scanner welding applications and quality assurance during the process can be found on the corresponding topic pages.