Across industries — from precision workshops to large-scale production lines — one thing is becoming increasingly clear: handheld laser welding is steadily replacing traditional methods like MIG and TIG.

As labor costs climb and demand for cleaner, faster welds grows, manufacturers are turning to smarter solutions that deliver more with less — and laser welding is leading the way.

In this article, you'll learn how to set up and operate a handheld laser welder — safely, efficiently, and without a steep learning curve. Whether you're upgrading from arc welding or just getting started, this article will walk you through every step.

Chapter 1：Introduction To Handheld Laser Welding

A handheld laser welding machine is a compact, portable device that uses a high-energy laser beam to fuse metal parts together. It enables precise, efficient, and low-distortion welding, especially for thin sheets, irregular components, and complex joints.

The machine integrates the laser source, handheld welding gun, and wire feeder into one streamlined unit. Compared to traditional manual welding tools like TIG or MIG welders, it offers easy setup, high integration, and intuitive operation — making it accessible even for operators with minimal welding experience.

Key Features:

• Reliable in Extreme Cold and Heat

• 100% Power, 100% Strong Welds

• Continuous Light Output

• Effortless Smart Knob Control

• More Than Welding — Cutting and Cleaning in One Machine

Chapter 2: Step-by-Step Process to Operate a Handheld Laser Welder

Before performing any operation, safety comes first.

• Never point the welding head at yourself or others.

• Always wear certified laser safety goggles and heat-resistant gloves.

• Operate in a laser-protected, enclosed workspace with fire safety measures.

• Keep bystanders and flammable materials at least 10 meters away.

• Avoid operating the machine in rainy or direct sunlight conditions to prevent humidity alarms or short circuits.

Once all safety checks are complete, follow the steps below to prepare, operate, and complete your welding task.

1. Create a Safe Environment

Check Equipment: Ensure the welding machine, gun, wire feeder, and cables are intact — with no damage, frayed wires, or loose parts.

→ Blue = neutral wire, Red = live wire, Yellow = ground wire. During operation, connect the live and neutral wires to the circuit breaker, and ensure the ground wire is properly grounded.

Verify Power Input: Make sure the input voltage matches the machine's specifications and remains within the recommended range.

Prepare Materials: Clean the workpiece surface to remove oil, rust, and dust. Choose welding wire that matches the base material and its thickness.

Wear Protective Gear: Always wear certified laser safety goggles, heat-resistant gloves, and protective clothing. In poorly ventilated environments, use a face shield and respiratory protection.

2. Assemble the Equipment

a. Install the Wire Feeder

Connect the wire feeding tube

Open the wire feeding wheel lock, insert the red wire feeding tube's inlet into the wire feeding device.

Install the wire feeding rollers

Unscrew the original wire feeding roller and replace it with a new one that matches the wire and nozzle diameter. Lock it tightly.

PS: Each roller has two sides with different groove sizes. If using 1.2mm wire, ensure the 1.2V is facing outwards.

Load the welding wire

Load the welding wire (5-30 kg supported; flux-cored wire not supported), pass it through the welding wire tube and two welding wire wheels, then enter the red welding wire tube. At last, fasten and lock the wire feeding wheel.

b. Assemble the Welding Gun

Install the nozzle

Insert the scale tube into the welding head dust port and adjust the scale to 0. Then install the nozzle and tighten.

Install the copper nozzle

Pass the wire feeding copper tube through the locking bracket at the welding head. Then turn on the wire feeder power switch, click the setting menu to switch the system. Then click the manual  wire feed button, when the welding wire passes through the wire feeding tube, install the copper nozzle.

Adjust distance

Adjust the distance between the copper nozzle and the welding nozzle to 1–2 mm.

3. Start Welding

Install the safety ground lock wire

Install the round power terminal of the safety ground lock wire to the welding machine ground lock wire connection column and tighten.

Open the gas cylinder

Insert the gas tube into the welding machine gas hole socket, open the gas cylinder and gas flow control switch. In the case of gas output, keep the gas flow not less than 15 liters per minute.

Use inert gases like nitrogen or argon with ≥ 99.99% purity and inlet pressure ≥ 0.3 bar for protection and cooling.

Adjust the welding parameters

Please refer to specific parameters according to BodorWelder manual or your experience.

Clamp the safety ground clamp

Clamp the safety ground clamp to the welding work table.

Start welding

Turn on the laser welder, hold the gun, and press the trigger to begin welding!

4. Post-Welding Shutdown & Maintenance

Power Down: Turn off the welding gun, wire feeder, and main unit in order.

Disconnect: After cooling, remove power cables, ground clamp, and gas tube safely.

Clean Workspace: Remove any spatter or residue, clean equipment surfaces, and store tools properly.

Routine Maintenance: Inspect and replace nozzles, lenses, and rollers as needed. Check cable integrity and lubricate moving parts regularly. Learn more about maintenance.

Chapter 3：Troubleshooting Common Laser Welding Problems

Even the most advanced machines may occasionally encounter issues. Here's a quick reference table to help you identify and resolve common alarms on your handheld laser welder — so you can get back to welding smoothly.

Frequently Asked Questions (FAQ)

Still have questions about handheld laser welding? Here are some of the most commonly asked queries from users — answered clearly and concisely to help you make the most of your Bodor machine.

Q1: Is handheld laser welding better than MIG or TIG?

Yes — for many use cases. Compared to traditional MIG or TIG welding, handheld laser welding offers:

• Faster welding speeds

• Minimal post-processing

• Cleaner weld seams

• Lower skill requirements

Q2: What materials can I weld with a handheld laser welder?

You can weld a variety of metals, including:

• Stainless steel

• Carbon steel

• Galvanized steel

• Aluminum

• Brass

Performance may vary depending on material thickness and reflectivity — use the proper laser settings and shielding gas for best results.

Q3: Do I always need a wire feeder?

Not always. Wire feeding is recommended when:

• Welding thicker sections

• Filling wide joints

• Improving joint strength

For thin plates, edge welding, or cosmetic seams, laser welding without wire is often sufficient.

Q4: How thick of a material can I weld?

It depends on the laser power and the type of metal. You can use the machine's built-in database to fine-tune the settings for different thicknesses and materials. The following are the maximum welding thicknesses for different power models.

Q5: Is handheld laser welding safe?

Yes, as long as proper safety measures are followed — such as wearing certified goggles, grounding the machine, and working in a protected environment. Unlike traditional TIG welding, which produces heavy smoke and arc light that can harm the eyes and lungs, laser welding offers a cleaner, healthier alternative for operators.

Which Handheld Laser Welder Fits You Best?

Whether you're running a factory that demands rugged, all-day performance or operating a mobile workshop that values compact flexibility — Bodor has a solution built for your workflow.

Not sure which model to choose? 

Here's a quick breakdown of Bodor's leading handheld laser welding machines, each designed for a different type of operation.

Learn more about handheld laser welding machines, please visit Bodor.