In this interview, Michael Wagener, Technical Director of Project Management at AK Industry, discusses the importance of a secure work environment in laser welding, with a focus on Germany and Europe. Based in Bavaria, AK Industry plays a key role in advancing safety standards in the European laser industry.
Can you briefly introduce yourself and AK Industry?
Michael Wagener: AK Industry, headquartered in Bad Wörishofen, Bavaria, is one of the largest providers of handheld laser welding systems in Europe. As a partner of THEO Laser Inc. for the DACH region (Germany, Austria, Switzerland), we’ve jointly developed a laser welding system tailored specifically to local requirements and meeting the highest safety standards.
We’re laser experts, offering concepts and solutions for industry in the areas of laser cutting, laser welding, laser marking, and laser cleaning – covering both handheld and automated processes for cleaning and welding. We place special emphasis on practical, safe, and efficient solutions for our customers. Currently, we employ 17 people and collaborate with active trade partners across the entire DACH region.
What role does your company play in laser welding and workplace safety?
Michael Wagener: Especially in the field of handheld laser welding, there are many safety-related aspects to consider, including protective equipment and the work environment. We support our customers from initial consultation through to the final implementation of the equipment, providing reliable, hands-on assistance as a partner to ensure safe and efficient use of the lasers.
Speaking of the work environment – how important is it for the safe operation of a laser welding system?
Michael Wagener: Extremely important. That’s why legislation sets clear requirements here. All distributors must adhere to the same safety standards without exception, which we fully support and implement.
For many companies, this means rethinking existing joining technology processes and redesigning the work environment accordingly. We actively guide this transition and work closely with local authorities and institutions to obtain the necessary official safety certifications. Our goal is to minimize potential hazards and prevent worst-case scenarios under all circumstances.
What are the biggest safety risks companies face when using laser welding systems?
Michael Wagener: For most users, the laser beam and the danger it poses feel abstract. Light that you can neither hear nor see seems harmless at first glance – but that’s exactly where the risk lies. Even brief exposure from uncontrolled reflections in the environment can cause significant damage. Just like with conventional welding methods, laser welding carries the risk of eye and skin damage. However, with laser welding – especially Class IV lasers – there are additional risks: while arc welding mainly damages the cornea through UV radiation (flash burns), the highly intense laser beam can penetrate deep into the eye and irreversibly damage the retina.
This is where our expertise comes in. We deliver targeted information about the potential dangers directly to the operator, because only through regular training and awareness measures can risks be minimized and safe handling of the technology ensured.
What should the ideal workplace for laser welding look like?
Michael Wagener: The legislator sets clear guidelines for a laser-safe environment. Fundamentally, it must be ensured that the operator works in a protected area and that bystanders are not exposed to laser radiation hazards. A laser welding cell or a separate room with the right safety features is key to a secure workplace. These include:
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Two-channel door contact switch – prevents the laser beam from being activated when the door is open (DIN EN 60825-1)
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Laser warning light – signals when the laser is in operation (DIN EN 60825-1)
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Protective windows/laser safety walls – reliably shield dangerous laser radiation (DIN EN 60825-4)
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Extraction system – reduces welding fumes and protects the operator’s respiratory system
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Lighting – supports precise work and reduces mistakes
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Warning signs (DIN EN 60825-1) – at every entrance, with info about the laser, potential hazards, and personal protective equipment (PPE)
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Fire extinguisher
In addition, attention should be paid to:
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Optimal operator positioning – the laser source directed away from the body and always standing behind the welding gun
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Use of PPE: complete, intact, and compliant with European standards (e.g., laser safety goggles per DIN EN 207 – more info here)
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Laser curtains as a room alternative – they provide flexible shielding of the work area for mobile welding applications (DIN EN 12254)
Additionally, laser processing machines and handheld laser devices must comply with DIN EN ISO 11553-1 or DIN EN ISO 11553-2 to ensure maximum safety.
Ventilation is a big topic – how important are modern extraction systems and the right filter technology?
Michael Wagener: Modern extraction systems play a crucial role in safety during laser welding. However, more isn’t always better – smart extraction (targeted, sensor- and demand-controlled, energy-efficient, monitored) is increasingly becoming a focus. One often overlooked aspect is proper fresh air supply. Many extraction systems focus solely on removing smoke and particles without ensuring balanced air intake. A draft-free, well-coordinated exhaust and supply air system is essential to maintain stable air quality and avoid unwanted turbulence.
Filter technology is equally critical: while effective extraction and filtration systems are standard in MIG or TIG welding, their use in laser welding is often neglected. Yet, laser welding also produces respirable dust that can penetrate deep into the lungs and cause serious illnesses. This dust can also affect component cleanliness, machine functionality, and weld stability.
As with TIG welding, laser welding should consistently follow TRGS 528 guidelines for capturing and filtering hazardous substances at their source, as well as the requirements of the Hazardous Substances Ordinance (GefStoffV) for modern extraction and filtration systems.
What role do proper lighting, room design, and ergonomic factors play in workplace safety?
Michael Wagener: In laser welding, adequate and well-placed lighting is essential. Compared to conventional welding, the molten pool is much smaller and produces far less visible light, which makes visibility challenging for the operator. At the same time, the fast process demands high movement coordination. Poorly lit environments can therefore not only lead to quality issues and rework – impacting employee satisfaction and production costs – but also increase the risk of tripping or accidents.
Room design and ergonomics (stable workpiece positioning, adjustable workstations, clear pathways) also play a vital role in the safety and efficiency of the welding process. Dry runs before actual work are a proven method to test the ergonomics of the work position and ensure the operator can perform movements optimally.
What technical solutions exist today to further improve safety in the welding environment?
Michael Wagener: Laser safety has been successfully used in industry for decades. Modern solutions rely on a combination of smart sensors, automated safety mechanisms, and advanced personal protective equipment:
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Sensor-based monitoring systems
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Air quality sensors to assess air quality and control filter technology
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Distance sensors on optics to ensure the correct distance between laser and workpiece, preventing misfocus
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Sensors for measuring stray radiation or reflections
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Active laser safety elements, like laser safety walls with detection systems that recognize direct exposure and trigger protective mechanisms integrated into a PLC (programmable logic controller)
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Smart PPE, such as laser safety helmets with integrated extraction
How can digitalization help further improve workplace safety?
Michael Wagener: Digitalization enables us to monitor and evaluate measures using sensors and automated systems to detect and respond to hazards in real time – whether through warning signals or automatic shutdowns. However, despite technological advances, it’s critical that employees and supervisors implement these measures daily.
What developments or trends do you see in the future for a “Secure Work Environment” in laser welding?
Michael Wagener: The future of safe work environments in laser welding will be shaped by intelligent, user-friendly safety concepts that autonomously detect hazards and immediately initiate countermeasures. These will continue to establish themselves in the market, even in areas that previously hadn’t considered using them. At the same time, they’re already setting a standard that both managers and operators can understand.
How often should safety checks be conducted to keep the work environment consistently safe?
Michael Wagener: Safety in laser welding requires regular, structured checks. This starts with daily verification of safety functions like the door contact switch, as well as checking the beam path and protective lenses – these should all be part of an operator’s daily routine. A continuous check for order and cleanliness should also be integrated into everyday work life.
What role does employee training play in implementing safety measures?
Michael Wagener: Training, such as the annual instruction required by the Laser Safety Ordinance, must be a regular part of workplace safety. However, it shouldn’t be limited to employees directly involved in the welding process within the cell. What good is the best training if colleagues in the surrounding area know nothing about it? Additionally, department or executive management should be well-informed about measures and safe applications in detail, because only lived practices can be actively implemented in operations.
If you could give companies just one key tip for a safe work environment in laser welding, what would it be?
Michael Wagener: Rely on expert knowledge and proven concepts. Safety in laser welding requires deep expertise – under no circumstances should you turn to Alibaba or TEMU. Individual consultation allows the work environment to be explained, challenges to be discussed, and a tailored solution to be developed. Partnering with a provider paves a safe path, reducing accident risks and downtime while saving money in the process.
Join us at THEO Academy
For more in-depth training on laser welding safety, join our online courses at THEO Academy. Our courses are designed to equip you with the knowledge and skills needed to create a safe and efficient laser welding environment.
