Laser-Based Manufacturing I Fundamentals

This course is the first in the Laser-Based Manufacturing Series and provides the foundational knowledge required for advanced study of laser processing technologies. Participants develop an understanding of laser operation, optics, beam behavior, safety, and the fundamental principles that govern laser-material interactions. Successful completion of this course is required before enrollment in one or both of the other two courses in the series: Laser-Based Manufacturing II: Laser-Material Interactions or a Laser-Based Manufacturing III: Synthesis & Projects.

This foundational course introduces the science, technology, and terminology of laser-based manufacturing. Participants develop an understanding of laser operation, beam behavior, optics, safety, and industrial laser systems, while building the technical foundation necessary for advanced laser-processing applications.

The course establishes the core concepts needed to understand how lasers generate, deliver, and control energy, as well as how that energy interacts with engineering materials. Participants gain the technical vocabulary and conceptual framework necessary to evaluate laser-based manufacturing processes and technologies.

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Who Should Attend?

Design and manufacturing engineers working with or transitioning to laser based processes.

Senior operators, technicians, and supervisors involved in laser system setup and maintenance.
Professionals in aerospace, automotive, or medical device industries seeking to enhance their laser capabilities.
Evaluate and select appropriate laser systems, process parameters, and quality metrics for various manufacturing applications.
Troubleshoot laser processes and identify root causes of defects and performance issues.
Apply laser safety standards and understand how process choices affect material and part outcomes.

What You Will Learn

Upon successful completion of this module, participants will be able to:

Explain the history, evolution, and role of lasers in modern manufacturing.
Apply laser safety principles and identify key hazards associated with industrial laser systems.
Describe the fundamental physics of laser operation, including stimulated emission, population inversion, and beam generation.
Explain the behavior of electromagnetic radiation and laser beam propagation.
Evaluate the function and impact of optical components on beam delivery and process performance.
Compare common industrial laser technologies and identify appropriate applications for each</p

Course Details: RA00145-E376

Course Outline

Introduction to Laser Manufacturing: History of lasers, industrial applications, laser safety, and the fundamental properties that distinguish laser light from conventional light sources.

Laser Generation and Optical Systems: Principles of laser operation, population inversion, optical components, beam delivery systems, and optical aberrations.

Laser Physics and Beam Characteristics: Energy transfer, laser modes, power stability, wave behavior, beam quality, and performance considerations.

Fundamentals of Laser-Material Interactions: Reflection, absorption, transmission, and the foundational mechanisms that govern how laser energy interacts with metals and non-metallic materials.

Course Schedule

Instructors and Program Director

Instructors
Frank Pfefferkorn
Dr. Frank Pfefferkorn is a Professor of Mechanical Engineering at the University of Wisconsin-Madison. His teaching and research are focused on discrete metal part manufacturing processes, and heat transfer as it applies to manufacturing processes. His goals are to: (1) educate/develop manufacturing engineers/workforce, and (2) build a scientific understanding of advanced manufacturing processes, develop physics-based models that can be used to improve and control these processes, and to transfer this fundamental knowledge to industry. In his lab he conducts research with a focus on where the tool meets the workpiece, whether that tool is a laser, mechanical cutting tool, friction stir tool, etc. Currently, his lab is conducting research on: friction stir welding and processing, placing sensors in the coatings of cutting tools for smart manufacturing, solid-state metal additive-subtractive manufacturing (including friction surfacing), and laser remelting surfaces for polishing, structuring, and hardening.
In addition to being an Professor in the Department of Mechanical Engineering he serves as the Academic Director of the online MS Manufacturing Systems Engineering Program at UW-Madison.
Kevin Klingbeil
Kevin Klingbeil is a seasoned expert in laser manufacturing processes with over 25 years of experience in process engineering, quality management, and technology leadership. He began his career after earning a physics degree from UW–Madison, initially working in automated circuit board inspection before advancing into laser-based manufacturing. His expertise spans laser welding, cutting, scoring, cladding, and heat treating across both metallic and non-metallic materials using a wide range of laser systems and wavelengths.
Kevin has consistently taken on both technical and leadership roles, including managing quality systems, developing embedded controls for galvo scanners, and directing multidisciplinary teams. He has also contributed to industry knowledge through conference presentations and client education. Currently, he leads his own consulting firm, Cross Product Solutions, helping manufacturers optimize laser processes and system integration.
Program Director
James Rink

Total Credits:

CEU 1,

Course Administration

Fee Information

Fee Covers Instruction and course materials

Discounts

Receive a 15% discount per person when you register eight or more from the same employer
Receive a 10% discount per person when you register three or more from the same employer.

Payment Options

If you are planning to attend an Interdisciplinary Professional Programs course, payment is required at the time of registration. Below are the payment options:

Pay by Credit Card

Enroll online and pay by credit card.

Search for the course on the website and then click on the Enroll Now button from the course webpage.
Enter all necessary course attendee information and payment information on the course enrollment page.
You will receive an email to confirm successful enrollment and payment.

Enroll over the phone and pay by credit card.

Call CERC Registrations at 608-262-2451.
Provide the registrations representative with:
- the course name, dates, and/or course number.
- the necessary course attendee information and payment information.
You will receive either a mailed document or an email to confirm successful enrollment payment.

Pay by Check

Mail in a completed registration form and check payable to UW Madison.

Fill out a registration form (found either in the back of the course brochure you received in the mail or here).
Prepare a check, made payable to UW Madison.
Mail the registration form and check to: CERC Registrations 21 N Park St, Ste 7101 Madison, WI 53715
You will receive either a mailed document or an email to confirm successful enrollment and payment.

Pay by Purchase Order

Request Purchase Order information from registration@cerc.wisc.edu
- If a fee quote is needed, contact custserv@interpro.wisc.edu first
You will receive an invoice from UW–Madison Business Services for payment, usually within 3–5 business days

Military

If using SF-182 form, please call our registration number at 608-262-2451 or email registration@cerc.wisc.edu for details and instructions.

Event Cancellation

We reserve the right to cancel a course due to insufficient enrollment or unforeseen events. If we cancel a course, participants will be notified via email or phone and will be given the option for a full refund or to transfer their registration and any fees paid to another course. We are not responsible for non-refundable plane tickets, hotel reservations, and other travel related expenses. For enrollee Course Cancellation, refer to notes on course page.

Cancellation Policy

If you cannot attend, please notify us by no later than one week before your course begins, and we will refund your fee. Because this course has limited enrollment, cancellation received after this date and no-shows are subject to the full course fee. You may enroll a substitute at any time before the course starts.