Welding isn’t just sparks and heat—it’s an essential (and often misunderstood) part of modern manufacturing. In this conversation, Ami Spira, General Manager of Civan Lasers USA, joins me to talk about the state of the art in welding technology and why laser welding is making such a big impact.
We cover how different welding methods work, what makes laser welding unique, and why Civan’s dynamic beam shaping enables new capabilities that weren’t possible before. We also dig into the engineering behind keyhole formation, melt pool control, and how to join dissimilar materials like aluminum and copper without compromising strength or conductivity. If you're designing or building physical products, there's a lot to take away here.
This isn’t surface-level talk. It’s a deep dive into the physics, materials science, and decision-making that go into modern manufacturing—and the cool engineering work that’s pushing it forward.
About AmiAmi Spira is the General Manager of Civan Lasers USA. He’s been with the company for over seven years, previously leading marketing and business development efforts before taking on the US leadership role in early 2024. Ami’s background spans B2B photonics, law, and business, but what stands out is how clearly he understands both the technical and strategic side of building something meaningful.
About Civan LasersCivan Lasers is pioneering Dynamic Beam Laser (DBL) technology, making it possible to weld thick and complex materials with speed, precision, and control. Their high-power, single-mode lasers with programmable beam shaping are enabling new possibilities in manufacturing, from automotive to aerospace to additive.
Key Takeaways
Traditional welding methods (like arc welding and MIG/TIG) are still widely used, but they have limitations in precision and speed.
Laser welding uses a highly concentrated stream of photons to deliver fast, precise joins with minimal heat-affected zones.
Dynamic beam shaping allows engineers to tailor the weld geometry, reduce defects, and join dissimilar or difficult materials.
Laser welding is unlocking new possibilities for materials like high-strength aluminum, diecast alloys, and copper-aluminum connections.
The ability to control the melt pool and keyhole in real-time is critical for quality and repeatability.
Manufacturing and design go hand-in-hand. Engineers who understand welding limitations can design better, more efficient parts.
Advances in automation and AI are reshaping how welding processes are developed, optimized, and executed.
Real innovation doesn’t just happen in new product design—it’s alive and well in how we build things, too.
Chapters
Intro to Laser Welding and Civan's Role
Welding Basics: Arc, Friction, and Laser
Challenges of Material Properties and Dissimilar Joins
What Makes Dynamic Beam Shaping Unique
How Lasers Penetrate Thick Sections with Precision
Design for Manufacturing: Why Welding Considerations Matter
Diecasting, AI, and What’s Next for Welding Innovation
Reflections on the Role of Engineering in Building the Future