Laser-Based Manufacturing

This course offers a deep dive into laser fundamentals, optics, and motion control, paired with hands-on insights from decades of industry and research experience. Participants will explore laser-material interactions, system setup, safety protocols, and troubleshooting techniques through interactive sessions and weekly applied learning. Whether you're new to laser manufacturing or looking to refine your expertise, this course equips you to make informed decisions and drive process improvements.

• 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 manufacturing capabilities.

This course is part of the Manufacturing Excellence Certificate. Course may be taken individually as well.

1. History of lasers and their applications
2. Laser Safety
3. Principles of laser operation and types of lasers
4. Electromagnetic (EM) radiation and wave propogation
5. Optics
6. Laser-material interactions
7. Laser implementation considerations and trouble shooting
8. Industrial manufacturing process applications of lasers:
   1. Marking
   2. Cleaning
   3. Heat treating
   4. Peening
   5. Forming
   6. Sintering and Welding
   7. Polishing and Structuring
   8. Cutting

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 Klingbell

Kevin Klingbell 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.