Laser safety

Laser safety: working safely with laser systems

When working with Class 4 laser systems, laser safety is essential. Although laser technology offers many advantages, particularly in terms of precision and speed, it also poses potential risks to eyes and skin. Laser welding systems from ALPHA LASER are very powerful and therefore require strict safety measures to ensure safe operation.

Comprehensive technical safety features integrated into the laser systems provide both operators and users with a high level of protection. Nevertheless, it is essential to comply with applicable safety regulations and to implement additional organizational and personal protective measures, especially when working with flexible laser systems without an enclosed working chamber.

ALPHA LASER has compiled the most important rules of laser safety as well as the classification of laser safety classes in a clear and structured way.

Laser classes: from scanner to laser welding machine

The different laser classes categorize laser products based on their potential for injury. The level of risk depends on the power of the laser. The classification is defined by the DIN EN 60825-1 standard.

Laser class	Safety measures	Typical applications
Class 1	Class 1 lasers are safe for normal use, as they do not emit harmful radiation or the radiation is limited to a safe level. No specific safety measures are required, but general caution when handling lasers is always recommended.	Barcode scanners and readers CD/DVD drives Laser printers and photocopiers Laser distance measuring devices Laser levels
Class 2	These lasers are visible and can damage the eye if the beam is viewed directly. However, they are generally considered safe, as the natural blink reflex provides sufficient protection. Safety measures include the use of protective eyewear to prevent accidental exposure and limiting exposure time.	Laser pointers (red or green) Lasers for presentations Simple laser measuring devices Some laser toys and entertainment lasers
Class 3R	Class 3R lasers can cause eye damage when the beam is viewed directly, but only with prolonged exposure. Safety measures include the use of protective eyewear with appropriate optical density, limiting exposure time, and implementing warning signs and safety precautions in the workplace.	Lasers for education and research Lasers for the entertainment industry (laser light shows) Some medical lasers for dermatology and ophthalmology Lasers for industrial applications such as alignment and positioning
Class 3B	These lasers can cause eye or skin damage if viewed directly or through unintended reflections. Safety measures for Class 3B lasers include the use of protective eyewear with appropriate optical density, limiting exposure time, wearing protective clothing and gloves, and implementing safety precautions in the workplace.	Lasers for medical applications such as surgery and therapy Industrial lasers for engraving, marking, and cutting materials Lasers for research and development in various disciplines High-power lasers for the entertainment industry (large events, concerts)
Class 4	Class 4 lasers represent the highest level of risk and can cause severe eye and skin injuries as well as fire hazards. In addition to direct radiation, diffuse radiation is also dangerous. Safety measures include suitable protective eyewear, protective clothing, restricted access, safety interlocks, personnel training, and emergency procedures.	High-power lasers for industrial cutting and welding applications (e.g. CO2 lasers, fiber lasers) Laser systems for material processing in the automotive and electronics industries Medical lasers for complex surgical procedures and tissue ablation Military lasers for weapon systems, targeting, and distance measurement Scientific lasers for research in physics, chemistry, and biology

Class 4 laser safety: integrated safety features by ALPHA LASER

The requirements outlined above demonstrate which safety measures are necessary for laser systems from ALPHA LASER that are classified as Class 4. Safety measures differ between enclosed and open laser systems.

Enclosed systems with a laser-safe working chamber are fully shielded workstations and require significantly fewer organizational measures, as only the operator’s hands are within the hazard zone.

Open, flexible laser systems offer maximum flexibility but can pose a risk to eyes and skin if used improperly. ALPHA LASER reduces this risk to a tolerable residual risk through comprehensive technical safety measures.

Examples of laser safety measures:

Key switch to prevent unauthorized use
Safety shutter to prevent unintended laser emission
Warning light indicating active laser radiation
Emergency stop button
Radiation protection shield for neck and face
Foot switch to prevent unintended activation
Safety modules to ensure functional safety
External warning light and door monitoring systems

However, complete safety cannot be ensured by design alone; operators and users of laser welding systems must also comply with Class 4 safety regulations.

On this basis, ALPHA LASER developed a test concept and planned a corresponding test setup. In this setup, the mechanical and optical adjustments were implemented functionally in order to verify feasibility under realistic conditions. After a successful feasibility study, the required functionality of the future machine was reviewed again and supplemented with additional aspects.

This step in particular demonstrates how customer-specific special solutions are developed in practice: not all requirements are fully defined from the outset. Some needs only arise during the use of the test setup. In this case, for example, the requirement was added to display and lock the angular position.

Safe, even in the event of a technical failure

ALPHA LASER is the only manufacturer worldwide whose open laser welding systems are TÜV-certified. All open laser systems feature certified functional safety in accordance with DIN EN ISO 13849 with Performance Level d (TÜV Süd).

Lucas Reichel

Before embarking on his journey in the realm of industrial engineering at Munich University of Applied Sciences, Lucas Reichel completed an apprenticeship as an electrician. This foundational experience not only equipped him with practical skills but also fueled his interest in the intersection of technology and business.

Furthering his education, Lucas earned a degree as a certified marketing manager, greatly enhancing his expertise and enriching his understanding of how these two fields intertwine. His career path has been diverse, encompassing roles in construction and electrical engineering, technical support, and ultimately leading him to the marketing department at ALPHA LASER.

Since 2016, Lucas has been a key player in the company, leveraging his interdisciplinary background to drive success. In his leadership position, he is responsible for shaping the strategic direction of marketing, crafting innovative concepts across digital and traditional platforms, and enhancing the international brand presence of ALPHA LASER.

What sets Lucas apart is his empathy and strong team spirit, allowing him to connect with people, streamline processes, and create sustainable solutions. His profound understanding of both technology and marketing makes him an essential pillar of the organization, always aiming to merge innovation with customer proximity.

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