What is the difference between conduction and keyhole welding?

Conduction welding uses lower power to melt and fuse material surfaces, creating wider, shallower welds. Keyhole welding uses higher power to create deep penetration through vaporization, ideal for thicker materials and butt joints.

What shielding gas should I use for laser welding?

Argon is commonly used for stainless steel and aluminum to provide protection and weld quality. Helium can be chosen for deeper penetration on some thicker materials. Nitrogen may be used for certain mild steel applications depending on your procedure, and some thin-gauge jobs use no shielding gas at all. Always follow your qualified welding procedures and supplier guidance when selecting shielding gas.

How much power do I need for laser welding?

Required laser power depends on material, thickness, weld geometry, and desired speed. Higher power generally allows faster welding or thicker sections, but also increases equipment and operating costs. Follow your equipment supplier’s recommended power levels for your applications and enter the actual power you plan to use into this calculator.

Why does welding cost more than cutting?

Welding requires higher precision, slower speeds, shielding gas, potential pre/post-heat treatment, and more stringent quality control. Setup time per piece is often higher, and skilled operators command higher wages. The profit margin also reflects the higher risk and quality requirements.

What factors affect welding speed?

Material type and thickness, laser power, welding process (conduction vs keyhole), joint fit-up quality, required penetration depth, and quality requirements. Aluminum welds faster than stainless steel. Keyhole welding is faster than conduction for thick materials.

Laser Welding Cost Calculator

Estimate laser welding costs for different processes and materials.⚠️ Estimates only - verify against production data

Welding Parameters

Welding Process

Material Type

Joint Type

Weld Specifications

Thickness (mm)

Weld Length (mm)

# of Welds

Seam Welding – typical use

Conduction is usually best for thin materials and cosmetic welds; keyhole for deeper penetration on thicker sections; seam for continuous joints; spot for discrete points. Match your process to material thickness and joint design.

Equipment

Laser Power (Watts)

Equipment Cost ($)

Lifespan (years)

Annual Hours

Operating Costs

Electricity ($/kWh)

Shielding Gas

Gas selection check

✅ Argon is a common choice for Mild Steel. Still follow your qualified welding procedures.

Gas Flow (L/min)

Gas Cost ($/m^3)

Labor ($/hr)

Overhead ($/hr)

Maintenance ($/hr)

Quality & Batch

Requires Preheat (+5 min)

Post Heat Treatment (+10 min)

Inspection Time (min)

Setup Time (min/batch)

Quantity per Batch

Weld quality class & inspection

Class A – stringent

Aerospace and pressure-vessel work with full NDT. Expect 5–15 minutes per part of inspection and documentation.

Class B – standard

Automotive and general industrial welds with visual plus spot checks. Typically 1–3 minutes per part.

Class C – basic

Prototypes and non-critical welds with a quick visual check under 1 minute per part.

Enter inspection time according to your quality class. Higher classes increase time and cost but reduce rework and risk.

Ready to Calculate

Enter your welding parameters and click "Calculate Cost" to see detailed analysis.

Welding Optimization Tips

Process Selection

- Compare conduction and keyhole modes for your thickness range using the welding process input
- Use seam welding settings for continuous joints and spot welding for discrete tack points where appropriate
- Reflect your actual procedure choices in the calculator so the time and cost outputs match your process plan

Cost Reduction

- Increase batch sizes where possible to spread setup time across more pieces, and adjust quantity per batch in the calculator to see the impact
- Use the shielding gas type, flow rate, and gas cost fields to compare different gas scenarios for cost versus quality
- Try different power levels and weld speeds within your qualified ranges to see how they influence hourly cost and cost per piece
- Regular maintenance and reliable equipment reduce unplanned downtime, which is not modeled directly but affects how many hours you can bill

Quality Improvement

- Maintain tight and consistent joint fit-up according to your welding procedure to help quality and repeatability
- Choose shielding gas and parameters that meet your material and quality requirements, then mirror those settings in the calculator
- If procedures require preheat or post-weld heat treatment, enable those options and add inspection time so related time is reflected in the estimate

Pricing Strategy

- Use the cost per piece and recommended price from this calculator as a starting point, then adjust margins based on project complexity and risk
- Consider setup fees for small batches where setup time is high relative to weld time
- Premium pricing for certified or high-spec welds can reflect additional qualification and inspection effort
- Offer volume discounts only where higher quantities genuinely improve your overall economics

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When to Choose Laser Welding

✓ Best for:

• Thin to medium sections where distortion matters
• High-precision parts and sealed joints
• Dissimilar materials and hard-to-reach joints
• High-volume, repeatable production

⚠️ Traditional welding may be better when:

• Fit-up gaps are large or inconsistent
• Very thick sections (>20 mm) dominate the job
• Work is mostly field welding or repair
• Lowest equipment cost is more important than speed

For capital decisions, combine this calculator with the ROI and Energy calculators to capture the full picture.

Important: Estimates Only

Results are based on simplified welding models and assume consistent joint fit-up, stable material properties, and typical shop practices. Actual costs depend on joint quality, material condition, qualified procedures, and inspection level.

Always test with your own welding procedures and compare against real job data before committing quotes.

Professional Calculators

Core Calculators

Cost Center

Analysis