A medical device standing by in a hospital setting.

Welding for medical devices often requires a very delicate and specific process; one that can be tailored to unique geometry and form autogenous welds (containing no filler material). Resistance welding and laser welding both fit the above criteria, but there are distinct differences between them that impact part design, process control, and the type of bond that is formed between components.

Here’s a quick comparison between resistance welding and laser welding:

Resistance Welding for Medical Devices

  • Heat is generated by an electric current, which softens and joins the metal (solid state bond).
  • Forms an internal weld, avoiding possible air contamination.
  • Excellent for welding fine foils and wires.

Laser Welding for Medical Devices

  • Absorbed energy melts the metals to form a bond (fusion weld).
  • Produces external welds, with only a small section of the component being exposed to the laser.
  • Several weld configuration choices, and especially ideal for for hermetic seam welds.

Further Reading on Welding for Medical Devices

One of our partners, Dr. Girish P. Kelkar of WJM Technologies has written an excellent primer on the subject, “Resistance and Laser Welding for Medical Devices”. With over 30 years of experience in the field, Dr. Kelkar has been a valuable resource as a consultant, and our technicians have taken advantage of his training courses as part of their professional development.

His article discusses:

  • Weld configurations for both resistance welding and laser welding
  • Types of bonds
  • Process control and monitoring
  • Weld testing and analysis


Every project and circumstance is unique. Contact one of our experts! We’re happy to make recommendations and answer any questions you may have.