Laser-Based Manufacturing III Synthesis & Projects

This course serves as Module III of the Laser-Based Manufacturing Series, focusing on the practical application of laser technologies in manufacturing environments. Participants apply the foundational concepts developed in Module I: Fundamentals of Laser-Based Manufacturing to evaluate manufacturing processes, troubleshoot performance issues, and explore emerging laser technologies;successful completion of Module I is required.

This application-focused module explores how laser technologies are implemented in industrial manufacturing environments. Participants may choose from a series of technical lectures and real-world case study discussions covering applications such as welding, cutting, additive manufacturing, heat treating, cleaning, marking, polishing, structuring, and laser-assisted manufacturing.

Emphasis is placed on process selection, system integration, troubleshooting, quality improvement, and emerging applications. Participants learn from both technical instruction and practical industry examples drawn from manufacturing environments.

Because laser manufacturing encompasses a wide variety of processes and applications, not every topic will be equally relevant to every participant. To give you flexibility while keeping you engaged with the materials, you can choose the sessions that best match your industry, role, and interests.

View course details

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:

Evaluate the suitability of laser-based manufacturing technologies for specific products and production environments.
Select appropriate laser systems, process parameters, and quality metrics for common manufacturing applications.
Diagnose common process defects and identify likely root causes.
Apply structured troubleshooting approaches to improve process capability, consistency, and productivity.
Assess tradeoffs among alternative laser manufacturing processes and implementation strategies.
Communicate technical recommendations for laser-based manufacturing solutions using engineering and business considerations.

Course Details: RA00151-E378

Course Outline

Surface Modification Processes: Laser heat treating, peening, bending, cleaning, and deburring applications used to enhance material and surface performance.
Marking and Laser-Assisted Manufacturing: Laser marking, product traceability, laser-assisted manufacturing methods, and process integration strategies.
Melting, Polishing, and Surface Engineering: Laser polishing, surface structuring, conduction-mode melting, and keyhole-mode processing.
Additive Manufacturing Applications: Laser-based additive manufacturing technologies, process capabilities, quality considerations, and production applications.
Laser Welding Technologies: Welding fundamentals, process selection, joint design, defect prevention, and troubleshooting methodologies.
Laser Cutting and Emerging Applications: Thermal and ultrafast laser cutting, precision material removal, process optimization, future technologies, and industry case studies.

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:

Course Administration

Fee Information

Fee Covers instruction and materials

Discounts

When eight or more sign up from same employer, your course discount is $75.
When three or more sign up from same employer, your course discount is $50.

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.