FLASH LAMP-PUMPED, MOBILE SYSTEMS OF 60 TO 500 WATTS
Sirius Light is a highly versatile, flash lamp-pumped laser welding system developed for industrial applications that demand both precision and flexibility. With a maximum range of 1830 mm and a load capacity up to 25 tons, it is engineered to perform even on the most complex and large-scale components. Its modular structure and robust construction make it ideal for deposition welding, especially in fields like aerospace, automotive, and heavy tool repair.
Thanks to its torsion-resistant frame and mobile design with swivel castors, Sirius Light ensures precise operation combined with maximum mobility. The system’s removable display and advanced control over laser parameters provide intuitive and efficient handling for professionals.
The Sirius Light is a high-performance, mobile laser welding system designed for the most demanding industrial applications. With its unmatched reach, heavy-duty load capacity, and robust modular build, Sirius Light redefines the standards for precision, flexibility, and mobility in laser welding. Developed by Sigma Laser, this system excels in deposition welding for large tools, molds, and components up to 25 tons in weight. Its compact design, integrated axis configuration, and advanced control interface make it ideal for a broad range of industries such as tool and mould making, aerospace, shipbuilding, and heavy machinery maintenance.
With a maximum radial reach of 1830 mm, Sirius Light ensures easy access to even the most complex workpieces. The stable construction mounted on swivel castors, pivoting arms, and detachable magnetic display ensure not only precise operation but also ease of handling and transport.
Equipment
- Pivoting Resonator & Motorized Z-Axis: For both laser resonator and work table, ensuring height adjustment and ergonomic positioning.
- Magnetic Display Panel: Easily detachable, ideal for transport and quick access to parameters.
- Leica Microscope: 10× magnification with 100 mm working distance for precise visual inspection.
- Twin Lamp Cavity (TLC): Enhances laser rod lifespan, beam stability, and performance.
- SPT Upgrade: Optional Super Pulse Technology available for welding special alloys like Inconel and high-temp steels.
- Mobile Design: Heavy-duty casters for effortless movement across shop floors.
Accessories
- Precise wire feed system
- Motor-driven rotary device
- Swiveling Y-axis & telescope lens optics
- Remote diagnostics module via internet
- advanced automation modules
Software
- Sigomatic: Basic display-based laser control with teach-in functionality for 2D/3D contours.
- Sigomatic Pro: Advanced PC-based solution with full automation support, especially suitable for serial and complex part welding.
The Sirius Light is more than just a laser source — it’s a complete, industrial-grade welding workstation that integrates advanced engineering, user-focused ergonomics, and modular automation options into one cohesive system.
From the moment of delivery, Sirius Light is fully equipped to perform complex welding tasks across multiple industries. The inclusion of a motorized Z-axis, pivoting resonator, and Leica microscope provides an ideal foundation for precision and repeatability. The detachable magnetic display ensures operational flexibility, allowing users to adapt control access based on workspace layout or safety preferences.
The software backbone of the system is equally robust:
- Sigomatic enables intuitive laser parameter adjustment, teach-in programming, and shape memory for repeatable results.
- Sigomatic Pro unlocks full CNC compatibility, multi-axis motion sequences, and remote diagnostics — turning Sirius Light into a fully automatable production unit.
In terms of motion capabilities, the base configuration supports X, Y, and Z-axis movement, while optional rotary (C-axis) modules and swivel-mounted optics extend the machine’s flexibility for 3D contours, circular weld paths, and workpieces with irregular geometry.
For those operating in heavy-duty, high-precision environments — such as aerospace, mold repair, and marine engine servicing — Sirius Light offers a balanced mix of power, control, and configurability, all in a mobile platform that’s built to evolve with your needs.
Whether you’re integrating into a production line or moving between workstations, Sirius Light is your all-in-one solution for professional laser welding performance.
Designed for industrial-grade performance, Sirius Light combines raw laser power with precision engineering.
Its robust construction, modular components, and wide range of configuration options make it one of the most flexible and reliable Nd:YAG laser welding systems on the market.
Below are the key technical parameters that define its unmatched capability in heavy-duty welding tasks:
🔹 Laser System Specifications
Parameter |
Specification |
Laser Type |
Flash Lamp-Pumped Nd:YAG (Neodymium-doped Yttrium Aluminum Garnet) |
Wavelength |
1064 nm (infrared) |
Average Power Output |
Configurable: 60 W / 120 W / 160 W / 220 W / 330 W / 420 W / 500 W |
Maximum Pulse Energy |
Up to 170 Joules (depending on model) |
Peak Pulse Power |
Up to 13 kW |
Pulse Duration |
0.5 ms to 50 ms (user adjustable) |
Repetition Rate |
0.5 Hz to 40 Hz |
Focus Spot Diameter |
0.2 mm to 2.0 mm |
Pulse Shaping |
Available on 120 W and above (customizable waveform profiles) |
Beam Expander |
Motorized beam expansion for adjustable focus depth |
Flashlamp Configuration |
Single or Twin Lamp Cavity (TLC) for increased lamp life and beam stability |
Laser Safety Class |
Class 1 (fully enclosed system, safe for standard environments) |
🔹 Motion and Axis System
Parameter |
Specification |
Axes (Standard) |
Motorized X, Y, and Z axes |
Additional Axis (Optional) |
Motorized C-axis (rotational) or custom external axes |
Traverse Path (X / Y / Z) |
X: 200 mm, Y: 200 mm, Z: 300 mm |
Extended Reach (Radial) |
Up to 1830 mm with pivot arm system |
Max Workpiece Height |
450 mm |
Worktable Load Capacity |
Up to 25 tons |
Axis Control Resolution |
0.01 mm (high-precision servo motors) |
Axis Speed |
Configurable per application (variable speed, safe for micro-positioning) |
🔹 Optical System
Parameter |
Specification |
Viewing Optics |
Leica 10× stereo microscope, 100 mm working distance |
Eyepiece Type |
Widefield, glasses-compatible |
LED Ring Light |
Integrated for weld zone illumination |
Camera System (Optional) |
Laser-safe camera for remote display/recording |
🔹 Cooling and Power Supply
Parameter |
Specification |
Cooling System |
Integrated closed-loop water cooling or external chiller (optional) |
Coolant Type |
Distilled water or Sigma-approved coolant |
Power Supply |
3-Phase, 380V / 50 Hz / 16 A (varies by configuration) |
Energy Efficiency |
High due to modular lamp control and auto-standby mode |
🔹 Control System & Software
Parameter |
Specification |
Detachable magnetic display with rotary encoder |
|
Software Options |
Sigomatic (standard), Sigomatic Pro (advanced automation & CNC) |
Programming |
No code required for standard; G-code available in Pro version |
Memory Storage |
50 welding programs standard, expandable to 100+ |
Supported via VPN-enabled Sigomatic system |
|
Languages Supported |
English, German, French; additional languages on request |
🔹 Dimensions & Weight
Parameter |
Specification |
System Dimensions (W × L × H) |
760 mm × 1300 mm × 1200 mm |
Net Weight |
Approx. 210 – 475 kg (depending on configuration and options) |
Footprint Requirement |
2.5 m² to 3.5 m² (recommended for full arm movement) |
Mobility |
Equipped with industrial-grade swivel castors + locking mechanism |
🔹 Environmental Requirements
Parameter |
Specification |
Ambient Temperature |
15–30 °C (recommended) |
Humidity |
Max. 70% (non-condensing) |
Noise Level |
< 60 dB under normal operating conditions |
Ventilation |
Standard room ventilation sufficient (Class 1 safety enclosure) |
Power, precision, and flexibility across industries
The Sirius Light laser welding system is built for versatility in the real world — where parts are large, geometries are complex, and precision is non-negotiable. With its extended reach, advanced motion control, and Nd:YAG power scaling, Sirius Light has become the go-to solution for industries that demand both heavy-duty capabilities and delicate handling of critical components.
Whether you’re restoring a worn mold or welding high-performance alloys in aerospace, Sirius Light delivers unmatched control, durability, and consistency.
Medical Technology
Although larger than tabletop welders, Sirius Light still serves medical device manufacturers and repair facilities that require both flexibility and superior weld quality. Its Leica microscope and ergonomic arm support fine positioning for surgical instruments, implantable devices, and stainless steel housings — all with reduced spatter and excellent cosmetic finish.
read more about Laser Welding application in Medical Device Manufacturing
Tool and Mould Making
Sirius Light is ideal for deposition welding and repair of large tools and molds — including those up to 25 tons. With its extended arm reach and stable Z-axis adjustment, it allows precise access to worn edges, cavities, or complex contours without disassembling the mold. The system’s Super Pulse Technology (SPT) ensures strong, clean welds that are free from cracks or porosity, even on hardened steel.
read more about Laser Solutions for Precision Tool and Moulding Industry
Aerospace Industry
Welding aerospace parts requires extreme accuracy and consistent quality — especially when working with exotic materials such as Inconel, titanium, and heat-resistant steels. Sirius Light delivers micron-level control thanks to its precision optics, stable laser output, and CNC upgrade options via Sigomatic Pro. It supports both R&D prototyping and maintenance of flight-critical components.
read more about Advanced Laser Welding Solutions for Aerospace Industry
Electrical & Mechanical Engineering
From circuit carriers to casing repairs and motor housings, Sirius Light enables precise welds on small to mid-sized electrical components — especially those requiring minimal heat distortion. With its adjustable beam diameter and low-energy welding profiles, delicate structures can be joined or reinforced without damaging insulation or surrounding parts.
read more about Laser Welding in the Electrical Devices Industry
Shipbuilding & Marine Engineering
In marine environments where accessibility is limited and downtime is costly, Sirius Light excels. The swivel-mounted optics and mobile design allow technicians to bring the welder directly to engine components, turbines, or pump housings. Its compact footprint and Class 1 safety enclosure make it a valuable tool for tight working conditions like ship engine rooms or hull interiors.
read more about Laser Welding for the Shipbuilding Industry
General Repair & Maintenance
Whether it's worn-out die inserts, broken edges, or surface damage, Sirius Light provides robust repair capabilities without removing the part from its environment. Its teach-in functionality allows fast setup and repeatable repair paths, making it ideal for service centers, tool shops, and maintenance departments.
Key Advantages Across Applications:
- Extended reach up to 1830 mm allows welding on large and complex parts without repositioning
- High weight capacity (up to 25 tons) supports massive tools and molds
- Mobile chassis with lockable casters offers portability across different workstations or production halls
- Configurable pulse parameters ensure adaptability from micro-welding to deep penetration jobs
- Ergonomic interface and optical system enable precision with minimal operator fatigue
- Full integration with automation or standalone use, supporting flexible workflows across industries
No two manufacturing environments are the same — and that’s why the Sirius Light is built with modularity at its core. From power scaling and axis extensions to automation-ready software and specialized optics, this system is engineered to adapt and grow with your production needs. Whether you’re upgrading an existing process or configuring a brand-new solution, Sirius Light can be personalized to match your materials, part sizes, and welding complexity — without sacrificing precision or stability.
Sirius Light is highly modular:
- Modular Power Levels: Start with 60W or scale up to 500W depending on need.
- Software Add-ons: Sigomatic & Sigomatic Pro software with teach-in functionality and automatic welding paths.
- Axis Extensions: Upgrade traverse paths or install telescopic arm modules for extra vertical clearance.
- Additional automation components
- Specialized optics and fixtures for custom applications.
Answers to common questions about the Sirius Light laser welding system
Sirius Light offers a rare combination of extended reach (up to 1830 mm), 25-ton load capacity, and modular laser power up to 500 W — all in a mobile platform. Its flexible motion control, detachable display, and advanced Sigomatic software make it ideal for both manual and automated workflows.
Absolutely. The system is designed to handle parts up to 25 tons and features swivel casters for mobility. You can bring the laser to the part instead of repositioning heavy equipment, saving time and minimizing risk.
Not at all. With Sigomatic, users can easily set parameters using a visual, touch-based interface. For advanced users, Sigomatic Pro supports teach-in paths and G-code compatibility — perfect for automation or serial production.
The system is suitable for tool steel, stainless steel, titanium, Inconel, copper alloys, and more. The optional Super Pulse Technology (SPT) enhances weld quality on difficult alloys by reducing spatter and heat input.
Yes. The system is modular — meaning you can upgrade laser power, extend axis ranges, or add CNC capabilities over time. It’s a long-term investment designed to scale with your business.
Basic maintenance includes cleaning optics, monitoring coolant levels, and scheduled lamp replacement. The system includes remote diagnostics via software, and Sigma provides full after-sales service and support.
- How to Weld Molds up to 25 Tons Using Sirius Light
- Comparison: Nd:YAG vs Fibre Lasers
- How to Choose the Right Laser Welding Power Level for Your Industry
- Step-by-Step: Setting Up Your First Weld Program on Sigomatic
- 10 Common Mistakes in Laser Welding and How to Avoid Them
- Maintenance Checklist for Your Sirius Light Welding System
- Laser Welding Safety: What Operators Must Know Before Using the Machine
- Optimizing Weld Parameters for Difficult Metals Like Titanium and Aluminum
- Understanding Pulse Energy, Frequency, and Duration in Nd:YAG Lasers
- Upgrading Sirius Light for New Alloys and Use Cases
- Remote Diagnostics with Sigomatic: A Step-by-Step Guide
At Sigma Laser, our commitment to excellence doesn’t end at delivery. The Sirius Light comes with a full suite of after-sales services designed to ensure optimal performance, operator confidence, and long-term value from your investment. Whether you’re a small workshop or a multinational manufacturer, our support ecosystem keeps your production running smoothly.
Performance Optimization Consulting
For customers with high-throughput needs or complex applications, we offer:
- Process auditing
- Automation optimization
- Custom software macros
- Fixture design and integration consulting
Installation & Commissioning
Our team provides on-site setup, system calibration, and full integration into your existing workspace or automation line. We ensure everything is optimized from day one — including safety checks, software configuration, and trial welds.
Spare Parts & Consumables
We maintain a well-stocked inventory of Replacement lamps, Optical components, Cooling units and Wear parts. Fast shipping worldwide ensures minimal downtime.
Remote Diagnostics & Global Support
From preventive maintenance to rapid troubleshooting, our global service team keeps your laser welding equipment running with minimal downtime through on‑site visits and secure remote diagnostics.
Operator Training & System Onboarding
Hands‑on training programs give your staff the skills to operate, maintain, and optimize Sigma laser welding systems safely and productively right from day one.
Extended Warranty & Lamp Breakage Protection
Enjoy long‑term peace of mind with comprehensive warranty coverage—including exclusive lamp break protection—for all light‑pumped laser welding systems.
Regular maintenance is essential to ensure the Sirius Light operates at full performance, maintains consistent weld quality, and minimizes downtime. Thanks to its modular design and industrial-grade components, this system is engineered for long service life with minimal maintenance overhead.
Below is a recommended preventive maintenance schedule along with practical tips to maximize uptime and laser longevity.
Daily Maintenance Tasks
Clean the microscope lens and protective glass with approved optical wipes.
-
Inspect the Weld Area:
Check the workspace for spatter, residue, or debris that could affect weld quality or part stability. -
Ventilation Check:
Ensure that airflow vents are unobstructed for proper heat dissipation. Check foot pedal and rotary controls for smooth operation.
Ensure secure power connections and that the emergency stop is operational.
Weekly Maintenance
-
Laser Cavity Inspection:
Visually inspect the cavity area for dust or discoloration. Avoid direct contact unless cleaning is needed. -
Cooling System Check:
- Verify water levels in the internal cooling system.
- Inspect for any leaks or unusual noises.
- Clean or replace filters as needed.
-
Foot Pedal and Rotary Controls:
Test response to ensure proper input for automated functions. - Axis motion check: Run the motorized X/Y/Z axes to detect noise or resistance.
- Cable and connector test: Ensure no signs of wear, heat damage, or looseness.
Monthly Maintenance
-
Replace or Clean Filters:
Air filters and water filters (if applicable) should be cleaned or replaced to maintain stable temperatures. -
Software Backup & Updates:
Backup welding programs and log data; check for available firmware or Sigomatic software updates. -
Check Fasteners:
Tighten any mechanical fasteners on the worktable or rotary devices to avoid misalignment.
Long-Term Preventive Maintenance
-
Lamp Life Monitoring:
Each lamp has a defined number of pulse cycles (typically ~2–4 million). Use the control interface to track usage and plan replacement in advance. -
Laser Rod Inspection:
Over time, the rod may become slightly misaligned or coated. Periodic inspection by a certified technician is advised. - Axis calibration: Precision check and tuning of motion system to avoid offset or vibration.
- Inspect safety systems: Verify function of interlocks, emergency stops, and casing seals.
-
Annual Service Visit (Optional):
Consider a certified Sigma technician visit annually to recalibrate optics, update software, and perform full diagnostics.
Pro Maintenance Tips
- Always use Sigma-approved cooling fluids to prevent mineral buildup.
- Never clean optics with alcohol or general glass cleaner.
- Never touch optics or lenses with bare fingers. always use lint-free gloves or tools.
Store spare parts (lamps, filters, optics) in a clean, dry, static-free environment.
- Keep a maintenance logbook to track interventions and lamp usage.
- Enable system alerts via the software to receive early warnings about water levels, temperature, or lamp errors.
Summary:
Consistent preventive maintenance is the key to long-lasting laser performance.
The Sirius Light is engineered to minimize service intervals and maximize uptime, but routine care ensures that its precision, safety, and productivity remain uncompromised. Whether you’re running small repairs or high-volume production, these tasks keep your laser system performing like day one.
Laser welding is a powerful industrial process, and safety is paramount. The Sirius Light is built with a Class 1 laser enclosure, meaning it is safe for operation in standard environments without exposing operators to laser radiation — but proper usage, training, and awareness remain essential.
Here’s how to ensure safe daily use of the system:
Laser Safety Classification
-
Class 1 (Fully Enclosed):
The system’s design prevents any accidental exposure to laser radiation during normal use. Internal interlocks prevent laser activation if panels are open or improperly sealed.
Personal Protective Equipment (PPE)
- While the Sirius Light is enclosed, use of laser-rated safety glasses (wavelength 1064 nm) is advised during setup or service with open panels.
- Gloves and protective clothing may be required when handling sharp, hot, or heavy workpieces.
| Task | Recommended PPE |
|---|---|
| Routine operation | No PPE required under closed housing |
| Maintenance (open casing) | Laser safety goggles (1064 nm rated) |
| Welding setup adjustments | Safety gloves, protective sleeves |
| Handling heavy components | Safety shoes, cut-resistant gloves |
| Optical cleaning or inspection | Anti-static gloves and lens-safe cloths |
Workspace Safety Requirements
- Ensure that the system is installed in a ventilated, dry, and stable area with proper clearance on all sides.
Install on a level, vibration-free surface to ensure axis stability.
- Avoid stacking materials around the enclosure that could block access or cooling airflow.
Avoid clutter around the system to allow proper access to emergency stop and power cut-off.
Ensure all users are aware of the Class 1 safety zone boundaries.
Place proper safety signage indicating laser equipment in use.
Electrical & Cooling System Safety
- Power supply should be 3-phase 380V, grounded properly.
- Only trained personnel should access internal components or electrical cabinets.
- Use only approved coolant fluids in the cooling system to prevent corrosion or leaks.
Use only Sigma-certified coolant; regularly check coolant levels and look for leaks.
Never run the laser if coolant is low or the system indicates temperature warnings.
Keep all power cables secured and free from obstruction or wear.
Software & Control Warnings
- The Sigomatic interface is equipped with real-time alerts for:
- Overheating
- Water level drop
- Lamp fault
- Interlock failures
- Never bypass safety interlocks or override alarms.
Emergency Procedures
- An emergency stop button is located on the front control panel. All motors and laser output halt instantly when pressed.
- Keep a Class C fire extinguisher nearby for electrical incidents.
- Ensure all staff are briefed on emergency shutdown and evacuation procedures.
Power Cutoff: Located on the back panel — disconnects the full system from power.
In case of accidental exposure or incident, stop operation immediately and report to safety supervisor.
Training & Access Control
- Only trained personnel should operate or maintain the machine.
- Use login access levels on the Sigomatic interface to restrict advanced settings to supervisors or engineers.
- Display safety signage around the unit to maintain operator awareness.
Safety Summary
While Sirius Light is designed for maximum safety with its enclosed Class 1 architecture, proper training, routine checks, and workspace discipline ensure the system runs safely for years to come.
Choosing the right laser welding system is a strategic investment. With so many options on the market — from entry-level bench-top welders to advanced fiber laser platforms — understanding how the Sirius Light compares is crucial for informed decision-making.
Below is a side-by-side comparison between Sirius Light and other typical laser welding systems, followed by a clear summary of its competitive advantages.
Comparison Table
Feature |
Sirius Light |
Entry-Level Welders |
Fiber Laser Systems |
Laser Type |
Nd:YAG |
Nd:YAG (Basic) |
Fiber |
Power Range |
60W – 500W |
60W – 200W |
300W – 1000W |
Automation Support |
Manual / Semi / Full (X/Y/Z/C) |
Manual only |
Full automation |
Weld Control |
Teach-in + Sigomatic Pro |
Manual control only |
CNC / CAM systems |
Visual Inspection |
Leica optics + optional video |
Basic magnifiers |
Optional camera |
Customizability |
Very high |
Low |
Medium |
User Training Required |
Minimal |
Moderate |
High |
Maintenance |
Lamp-based (predictable) |
Lamp-based |
Fiber degradation over time |
Price Range |
Mid to high |
Low |
High to premium |
Best For |
Toolmaking, medical, repair, R&D |
Small repairs |
High-volume production |
Safety Class |
Class 1 (fully enclosed) |
Often open (Class 4) |
Class 1 |
Compared to traditional stationary systems, Sirius Light offers:
- Higher flexibility due to its mobile build and axis range
- Modular power configuration for future scalability
- Superior user interface via Sigomatic software
- Faster ROI due to reduced downtime and repair costs
Competitors often lack Sigma’s proprietary TLC system, which doubles lamp life and reduces beam instability.
Operator-Focused Ergonomics & User Experience
Unlike many laser systems that prioritize only technical specs, Sirius Light prioritizes comfort. The adjustable Z-axes for both the work table and laser head allow for fatigue-free operation. Whether standing or seated, users benefit from optimal ergonomics during extended welding sessions.
Bottom Line:
The Sirius Light stands out as a powerful, mobile, modular, and user-friendly solution — delivering industrial-grade results with human-centered design.
