Industry is faced with ever increasing requirements with respect to productivity, quality, equipment utilization and overall customer satisfaction. As the saying goes, “if you always do as you always did you’ll always get what you always got”. To change this paradigm, one must use more intelligent technology. To this end, a series of “smart laser tools” have been developed to optimize the laser welding process. The sensors systems operate in an integrated mode to enable precision 3D seam tracking, adaptive welding, process monitoring and weld quality verification. These tools can be used to monitor, control and optimize the welding operation. New high speed digital processing has made this a reality and the present benefits and future possibilities will be covered in this paper.

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