What is the Difference Between Spot Welding and Laser Welding?

What is Spot Welding and Laser Welding?

Spot welding is a type of resistance welding that uses electrical current and pressure to join overlapping metal sheets. Heat is generated at specific contact points (“spots”) due to the resistance between the materials, melting them locally and forming a bond under pressure. It is a widely used method for joining thin metal sheets, especially in automotive and appliance manufacturing.

Laser welding, on the other hand, is a non-contact process that uses a focused, high-energy laser beam to melt and join metals. It produces deep, narrow welds with high precision and minimal thermal distortion, and is suitable for a wide range of metals, including aluminum, copper, and even dissimilar materials. Laser welding is highly adaptable to automated production lines and is increasingly used in high-end manufacturing industries.

Features of Spot Welding and Laser Welding

Spot welding is simple, fast, and cost-effective for joining thin sheet metals, especially where high precision is not a primary concern. However, it is limited by electrode wear, visible weld marks, and challenges in automation and material compatibility (e.g., aluminum and copper).

Laser welding offers many advantages:

Non-contact process with no electrode wear

Minimal heat-affected zone, reducing warping and discoloration

High precision, capable of ultra-fine and deep welds

Fast welding speeds, ideal for automated, high-throughput environments

Compatible with difficult-to-weld materials, such as copper and aluminum

Beautiful, clean weld appearance, reducing or eliminating post-processing

At Huiyao Laser, we offer laser welding solutions that are optimized for both performance and cost. According to customer budget and process requirements, we integrate IPG ring-shaped spot fiber lasers for premium welding performance, or Raycus (锐科) fiber lasers for cost-effective, stable welding. The IPG ring beam offers superior energy distribution and control, especially useful in battery pack welding and dissimilar metal joints, while Raycus lasers provide stable quality at a competitive price.

Applications of Spot and Laser Welding

Spot welding is still widely used in industries such as:

Automotive body manufacturing

Household appliances (refrigerators, ovens, etc.)

Sheet metal cabinets and HVAC units

Small-scale battery assembly

Laser welding has become the preferred option for:

EV battery production: cell-to-tab, module-to-pack welding

Energy storage system assembly

Consumer electronics: precision parts, shells, and connectors

Medical device manufacturing: surgical tools and implants

Aerospace and high-end automotive: lightweight structural parts

Industrial power equipment: busbars, frames, and housing welding

How to Select Spot Welding or Laser Welding?

When deciding between spot welding and laser welding, consider the following:

If your product involves simple joints, thin steel, and visible welds are acceptable, spot welding is an economical choice.

If you require high welding strength, aesthetic welds, minimal thermal damage, and automated production, laser welding is more suitable.

For battery welding, laser welding is highly recommended due to its precision, speed, and compatibility with copper, aluminum, and nickel.

If you are concerned about budget, Huiyao Laser can provide options:

IPG ring beam for advanced, high-quality applications

Raycus lasers for practical, budget-friendly solutions

Supplier of Laser Welding – Huiyao Laser

Huiyao Laser is a professional manufacturer of laser welding equipment and automation systems. Based in Luoyang, China, we focus on:

Customized laser welding systems for battery, electronics, and precision metal

Full-process Pack lines for prismatic, pouch, and cylindrical cells

Robotic welding + vision positioning + MES integration

Global delivery and technical support services

We offer flexible laser source options, including IPG and Raycus, to meet diverse project needs from cost control to high-end performance. With strong R&D and production capability, Huiyao Laser is your trusted partner in welding automation.