Elettrolaser Industrial Laser Systems and Welding Machines

The Elettrolaser manufacturer

Elettrolaser S.r.l. was founded in Sona (Verona, Italy) and operates as a premier designer and manufacturer of precision laser systems for micro-welding, marking, engraving, and metal cutting. All equipment is certified to European CE safety directives and Industry 4.0 connectivity standards.

Pulsed Nd:YAG Laser Welding Technology: Smooth Gaussian Spot and Dual Cooling

Elettrolaser pulsed solid-state Nd:YAG laser systems (1064 nm wavelength) are engineered for high-precision micro-welding, spot joining, and seam welding without thermal distortion or structural embrittlement.

In the flagship Mega series welders, the proprietary Smooth Gaussian Spot beam shaping technology delivers a perfectly uniform energy distribution from the core to the perimeter of the optical spot.

This eliminates peak hot spots within the molten pool, preventing spatter, porosity, and crater cracking.

To ensure uninterrupted duty cycles under demanding multi-shift industrial production, Mega 6.0 and Mega 9.0 models feature an integrated Dual Cooling System.

Incorporating dual liquid-to-air heat exchangers, high-capacity circulation pumps, and oversized fluid reservoirs, this architecture maintains tight thermal equilibrium across the Nd:YAG cavity even in tropical ambient conditions exceeding +35 °C, delivering consistent pulse-to-pulse energy up to

255 J and peak power up to 10 kW.

Welding High-Reflectivity Precious and Reactive Alloys: Silver, Gold, Platinum, Titanium

Joining precious jewelry metals and specialized aerospace alloys poses severe metallurgical challenges due to high optical reflectivity (up to 95% for polished silver and copper at 1064 nm) and elevated thermal conductivity.

Elettrolaser advanced Pulse Shaping firmware allows operators to configure customized multi-segment pulse profiles, firing a high-power micro-spike to break surface reflectivity before smoothly transitioning into the controlled puddle-fusion plateau.

For welding reactive titanium, tantalum, and dental cobalt-chromium alloys, the welding chamber integrates an adjustable micro-nozzle for coaxial argon shielding gas delivery with programmable pre-gas and post-gas timings.

Shielding the weld pool from atmospheric oxygen and nitrogen prevents discoloration, eliminates interstitial brittleness, and produces mirror-smooth weld fillets across fine jewelry and medical implants.

Master 4.0 Ergonomics, Leica 10x Stereo Optics, and Industry 4.0 Connectivity

The Master 4.0 and MS 3.5 benchtop welding stations are built around operator comfort during extended assembly shifts. An inclined front fascia is paired with soft, ergonomically contoured polyurethane armrests to minimize shoulder fatigue.

Microscopic joint inspection is conducted through a Leica binocular stereo microscope offering 10x magnification, an expansive field of view, and an ultra-fast liquid crystal shutter (LCD shutter) that turns dark within microseconds prior to laser emission, providing certified 100% eye safety.

The Generation 4.0 architecture incorporates a vibrant 7-inch color capacitive touchscreen complemented by an interior chamber joystick. Operators can adjust spot diameter (from 0.1 to 2.0 mm), pulse duration, and capacitor voltage without removing their eyes from the eyepieces.

Integrated RJ-45 Ethernet and wireless Wi-Fi interfaces link the unit to factory supervisory networks, enabling flash-lamp telemetry monitoring, weld-parameter logging, and remote factory diagnostic sessions.

Portable Micro-Welding with DaDo: Forced-Air Cooling and Smartphone Control

Engineered for boutique jewelry workshops, optical frame repair counters, dental technicians, and mobile maintenance specialists, the DaDo and DaDo 2.0 represent an ultra-compact cubic welding platform weighing only 15 kg.

Operating from standard single-phase 110–230 V electrical mains with peak power draw under 1.8 kW, the machine features a clean forced-air cooling system that completely removes the need for demineralized water, fluid pumps, and radiator maintenance.

Welding parameters are configured wirelessly from any smartphone or tablet via the dedicated DaDo mobile application (iOS/Android).

The operator simply selects the metal grade (gold, silver, titanium, steel) and thickness, allowing the intelligent algorithm to calculate optimal pulse energy (up to 10.8 J).

An integrated LED targeting reticle and argon shielding nozzle ensure rapid positioning and secure, non-destructive tack welds without damaging heat-sensitive gemstones or enameled dials.

Automated Welding Systems: AWL, DL 200, and Turnkey Workcell Integration

For high-volume sensor manufacturing, medical electronics, hermetic relay sealing, and precision mechanical assembly, Elettrolaser supplies the AWL (Automatic Welding Laser), DL 200, and Combo 200 automated laser workcells.

Depending on throughput requirements, workcells are configured with either pulsed Nd:YAG resonators or continuous-wave/quasi-continuous-wave (CW/QCW) fiber laser engines ranging from 200 W to 2 kW output power.

The motion system features high-precision CNC multi-axis positioning tables (X-Y-Z plus rotary C-axis) driven by precision ground ballscrews or direct-drive linear motors.

Workcells are outfitted with high-resolution machine vision alignment cameras, motorized filler wire feeders handling wire diameters from 0.2 to 0.8 mm, and industrial fieldbus gateways (Profinet, EtherCAT) for closed-loop coordination with six-axis articulated industrial robots.

Fiberlux Laser Marking: Ytterbium Resonators, MOPA Modularity, and 3D Contouring

The Fiberlux family of fiber laser markers (including Nano, PRO, EL, and 3D variants) utilizes maintenance-free ytterbium fiber laser resonators with diode operating lifetimes exceeding 50,000 hours.

The high beam quality (M2 < 1.3), paired with high-speed digital galvo scanning optics, enables linear scan speeds up to 7,000 mm/s and character positioning repeatability within 10–20 microns.

Models equipped with MOPA (Master Oscillator Power Amplifier) architecture allow independent adjustment of pulse repetition rate (up to 1 MHz) and pulse duration (from 2 to 500 ns).

This capability enables high-contrast black marking on anodized aluminum, micro-cutting of thin gold foils without thermal slag, and brilliant color annealing on titanium and stainless steel.

The Fiberlux 3D model incorporates a dynamic focal lens to mark inclined, curved, and stepped geometries with up to 40 mm height variations.

Heavy-Duty Luxmark Workstations and Opera Sheet Metal Cutting Centers

For deep structural engraving of steel stamps, barcode marking of large automotive castings, and industrial sheet cutting, Elettrolaser builds the Luxmark series (Luxmark S, MeTop, W15, W72).

Fully enclosed in a Class 1 laser safety cabinet with a pneumatic vertical door and certified laser-safe inspection window, Luxmark units can be outfitted with a dual optical engine pairing a fiber laser for metals with a CO2 laser for polymers, wood, and technical textiles.

For serial blanking of precious metal sheet stock, medical stent components, and titanium brackets, the Opera cutting center provides an optimized platform.

Featuring fiber laser power up to 1000 W, a monolithic granite base, linear motor drives capable of 1.5G acceleration, and an automated optical sheet registration camera, Opera achieves exceptional kerf precision while heavy-duty recovery drawers collect 100% of high-value precious metal swarf and

dust.

Die Repair Laser Deposition Welding and Tool Steel Restoration

Refurbishing worn parting lines, damaged gate bushings, and cracked stamping punches in injection molds and die-casting tooling demands localized material deposition without tempering surrounding base metal.

Elettrolaser Die Repair systems pair a high-energy pulsed laser with an articulated balance arm and articulating optical head that maneuvers laser energy into deep mold cavities and massive dies weighing several tons.

With a minimal heat-affected zone (0.1–0.2 mm), high-hardness tool steel wires (H13, P20, Stellite, beryllium copper) from 0.1 mm diameter are deposited with metallurgical bonding and zero structural porosity.

Mold repairs are completed directly on the press or shop floor, eliminating costly mold disassembly, preheating, stress-relieving cycles, and lead times.

Factory Maintenance Standards and Optical Consumable Spare Parts

Peak optical efficiency and beam consistency in Elettrolaser pulsed welding equipment depend upon proactive maintenance of the optical resonator and cooling circuits.

The primary consumable in Nd:YAG resonators is the pulsed xenon flash lamp: as cathode erosion progresses past 3–8 million flashes, output irradiance degrades, requiring original lamp replacements to preserve Nd:YAG rod longevity and power supply health.

High-transmission quartz cover slides protect expensive internal focusing optics and Leica microscope lenses from molten spatter and flux vapors. Slides should be inspected daily and cleaned or replaced upon spotting pitting or carbon burn-in.

Cooling loops in Mega and Master welders require semi-annual changes of demineralized water and deionizing resin filter cartridges to prevent electrical flashover across lamp electrodes.