Handheld laser welding is changing the welding industry, but how much of the hype is backed by actual testing, and where does this technology fit into the future of fabrication?
In this special edition of Weld Wednesdays with AWS, recorded live at FABTECH 2026 in Las Vegas, I'm joined by Rex Alexandre from the Handheld Laser Institute. Rex is a former SpaceX welding engineer who helped develop laser welding applications for the aerospace industry before launching his own company focused on research, training, and advancing handheld laser technology.
We get into the technical side of handheld laser welding, including the process variables that affect penetration, weld quality, and repeatability. Rex explains why laser power isn't the only thing that matters, how beam spot size and wire feed speed influence the process, and why joint fit-up can make or break a successful laser weld.
We also discuss some of the biggest concerns surrounding this technology, particularly laser safety, proper eye protection, controlled welding areas, and the importance of understanding what you're buying before investing in equipment.
One of the most interesting parts of our conversation is Rex's work with structural applications. His team has successfully performed mechanical testing on 3/8-inch A36 plate welded using handheld laser equipment, opening up some interesting possibilities beyond traditional sheet metal applications.
We also cover the current state of welding codes and standards, including AWS and ASME, the challenges of qualifying handheld laser welding procedures, and what the industry needs to do to make this technology more accessible.
Whether you're a welder, welding inspector, educator, engineer, or shop owner considering adding laser welding to your operation, this episode offers a practical look at what the technology can and cannot do.
Weld Wednesdays with AWS is brought to you by the American Welding Society.
Stay safe out there, and until next time… make every weld better than your last.
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