Laser Welding vs Soldering: What Labs Need to Know

In many Australian dental labs, traditional soldering is still widely used for joining and repairing metal components in appliances such as partial frameworks and orthodontic devices, despite digital workflows and new alloys transforming the rest of the production process. However, as customer expectations continue to increase, particularly around appliance fit, reduced remakes, faster turnaround times, and overall production efficiency, many labs are reviewing which joining methods best suit different types of work. Traditional soldering remains a reliable solution for a range of applications, while laser welding is becoming an attractive option for tasks that require higher precision with speed, such as complex implant bars, delicate partial frameworks, and components produced through CAD/CAM milling or additive manufacturing.

Laser welding offers a different approach to energy input and joint design that can improve joint integrity, minimise re‑work and align more closely with modern materials and digital processes.

This article compares laser welding and soldering from a practical laboratory perspective, focusing on joint quality, throughput, technician workload, and total cost. It begins by examining the fundamentals: joint quality, heat input, and distortion control.

Joint quality, heat input and distortion control

Joint integrity begins with controlling heat. Soldering relies on heating the parent structures and flowing an intermediate alloy through a capillary gap. This exposes a relatively large area to elevated temperatures, which can soften or distort thin sections and introduce oxide layers that require aggressive cleanup. Laser welding, by contrast, focuses energy on a small spot for a brief pulse, producing a narrow, deep fusion zone with a minimal heat-affected zone. The result is near zero distortion, a reduced risk of colour changes in adjacent aesthetic components, and a cleaner surface finish that requires less re-finishing, all in a fraction of the time.

For standard repair tasks, such as closing a fracture in a clasp, adding a connector, or reattaching a broken component, well-tuned laser parameters (pulse energy, pulse duration, repetition rate, and spot size) routinely yield joints with high tensile and fatigue performance.

The ability to weld directly on the master model under magnification further improves accuracy. Shielding gas is critical: for titanium and other reactive alloys, an argon shield prevents the absorption of oxygen and nitrogen, which can cause weld defects. CoCr, commonly used for partial frameworks, also benefits from controlled heat input to limit carbide precipitation and hardness spikes that complicate finishing.

Metallurgical outcomes matter over the long term: solder joints incorporate a third alloy that can become the weak link under cyclic loading or in corrosive environments, whereas autogenous or filler-assisted laser welds maintain chemistry closer to that of the base metal.

Selecting the correct joint design is crucial. V‑grooves for penetration, lap or butt joints for specific geometries, and preparing clean, oxide-free surfaces are essential for both techniques. For clinics and labs integrating digital workflows, laser welding complements CAD/CAM and additive manufacturing by enabling targeted, low-distortion adjustments and repairs to milled or printed components.

For a look at compatible materials, explore options like CoCr or NiCr welding wires, rematitan® titanium, or remanium^® star milling blanks or powders for laser melting. 

Quality, capacity and return on investment

Speed and consistency are essential to the performance of successful labs.

Laser welding excels at rapid, repeatable spot and seam delivery. Energy is applied in short, high-power pulses with minimal thermal lag, allowing operators to stitch together frameworks with excellent positional control in spot, spots or continuous seams.

The lack of flux and the dry process simplify cleanup, and many joints can be completed directly on the master model thanks to the very localised heat-affected zone (HAZ).

Technicians report reduced distortion, which translates into less post-weld adjustment and re-finishing. With appropriate training, technicians quickly learn to dial in pulse energy, duration and repetition rate for typical joint geometries.

Modern tabletop systems such as Dentaurum's desktop Compact Laser Welder4 and Laser Welder SL10 are designed to minimise fatigue with large working chambers, inclined laser axes, bright fields of view, and intuitive touchscreen presets. These ergonomic features keep cycle times predictable over long shifts.

Using argon creates a clean, oxygen-free environment that prevents oxidation and contamination during welding. This helps produce stronger, more reliable joints and reduces the risk of brittleness or porosity—especially important when working with delicate frameworks or high-precision digital components. Argon also stabilises the laser plume, resulting in smoother energy delivery and a cleaner, more attractive surface finish.

Traditional soldering, on the other hand, is a familiar and accessible process. Oxygen–gas torches and investment fixtures are common, and technicians are comfortable with capillary flow and gap design. However, throughput is often limited by setup (investment, flux application, pre‑heat), the need to strip oxides and residues after soldering, and a greater propensity for distortion that can compromise marginal fits.

For multi-unit frameworks or delicate components, repeated heat cycles raise the risk of microstructural changes and warping.

From a training perspective, both methods require skill, but laser welding’s parametric presets and visual feedback significantly shorten the learning curve once basic safety and technique are established. Well-structured operating procedures, including calibration checks under magnification, help maintain consistency and accuracy. Lasers give technicians fine control that is difficult to replicate with flame. 

Compact Laser Welder 4 – compact power for daily lab welding

Dentaurum’s Compact Laser Welder 4 is designed as a high-performance tabletop unit for everyday laboratory work, where precision and ergonomics are crucial. Its compact footprint and generous working chamber make it easy to integrate into existing benches. Additionally, the inclined laser axis, bright microscope field, and intuitive touchscreen presets facilitate accurate positioning for clasp repairs, connector additions, and implant bars. A high power reserve and finely adjustable pulse parameters help stabilise melt pools on CoCr and titanium, allowing technicians to work directly on the master model with minimal distortion and predictable, repeatable results.

Laser Welder SL10 – flexibility for complex, mixed‑metal cases

For laboratories requiring even greater flexibility across complex frameworks and mixed‑metal workflows, the Laser Welder SL10 combines robust output with an ergonomically optimised chamber and a wide field of view. Its user-friendly interface, stored parameter sets, and responsive pulse control support both experienced technicians and teams new to laser welding, shortening the learning curve while maintaining weld quality.

Huge equipment sale

Dentaurum Australia is currently running an end‑of‑year promotion on all equipment, including laser welders, as well as CAD/CAM materials. To review current offers and bundle options tailored to your lab, please contact the Dentaurum Australia team.