Does laser radiation really threaten operators? With the right approach, a laser workstation can be one of the safest in the entire facility. Are you responsible for safety and implementing new technologies in your company? Check what decisions to make right from the start to eliminate 99% of the risk.
Is laser radiation dangerous? What is it and what risks does it carry?
An industrial laser beam is powerfully concentrated energy. It's thousands of watts focused at a point with a diameter of a fraction of a millimeter. And precisely for this reason, it poses a potential threat that can cause various effects.
What is the impact of laser on the human body? What dangers does it pose to eyes and skin?
Eye hazards
The greatest attention should be paid to eye protection. Direct, unprotected exposure to laser causes eye injuries. This can lead to permanent retinal damage. Many industrial lasers emit radiation in the infrared wavelength range invisible to humans. The result? Even in cases of short-term exposure, instinctive defensive reactions such as blinking will not work in humans. The threat is real but invisible, therefore it requires conscious and specialized protection.
Skin hazards
Direct contact with the beam can cause skin damage in the form of thermal burns. This risk, like in the case of eyes, applies only to situations of direct "hit" by the laser beam. You can effectively eliminate this risk thanks to flame-resistant clothing and special gloves.
Other hazards in laser processing, or how to manage the work environment around the laser
Air quality – dust and gases
The laser beam, melting and vaporizing metal, generates so-called process contaminants (LGAC). These are mainly submicron particles of metal oxides. For this reason, the concentrations of harmful factors should be regularly measured at workstations. Contaminants require effective elimination from the air. When processing certain materials, such as stainless steel, compounds such as chromium VI may be formed, which are potentially dangerous. Therefore, a key element of every workstation is an extraction and filtration system that continuously purifies the air and ensures safe working conditions.
Fire safety
The high temperature of the cutting process means that flammable materials should not be present in the work zone. Reflected beam or hot sparks are hazards coming directly from the process, which make fire hazards real. Maintaining cleanliness and order at the workstation is a fundamental OHS principle. Regular removal of metal dust and waste minimizes risk, and standard equipment with appropriate fire extinguishers (e.g., CO₂ or powder for metals) provides additional protection.
Noise level
Although the laser itself operates quietly, its auxiliary systems – such as compressors, extraction fans or cooling – generate sound at the level of 65–85 dB. This is a value comparable to or lower than many traditional machines (e.g., punching presses often exceed 90 dB). Nevertheless, during long-term work, standard practice is to monitor noise levels and, if necessary, use hearing protection.
Laser vs. other processing technologies - safety comparison
How does laser perform compared to traditional methods? With proper implementation, excellently.
Laser vs. MIG/MAG, TIG welding
Arc welding means a shower of sparks, intense UV radiation and clouds of smoke. Laser welding generates significantly fewer sparks, which minimizes the risk of burns. It also doesn't emit such strong UV. The amount of smoke is smaller because the process is more precise and doesn't require fluxes. As a result, the work environment is cleaner and the welder is less exposed.
Safety is just one of many advantages of this technology. If you want to learn more about the process itself, its parameters and applications, check our complete laser welding guide.
Laser vs. plasma/oxy cutting
Modern laser cutting machines are most often Class 1 safety devices, which under normal operating conditions are usually safe. This means they are fully enclosed and eye protection is provided without the need to use additional shields. During normal work, no dangerous radiation escapes outside. The operator can safely observe the process through a certified window. Plasma tables are often open, and the plasma arc is visible throughout the hall. Laser also eliminates the need to work with flammable gases like acetylene.
Laser vs. mechanical processing
You can't cut your finger with a laser. There are no rotating blades, guillotine knives or press punches. The risk of mechanical injuries – crushing and amputation – disappears. There are also no vibrations and deafening noise of punching machines. Hazards with laser are mainly optical and electrical but easier to completely isolate from the operator.
Protection measures - how to secure the workplace from laser radiation?
The principle is simple: risk must be eliminated, not just managed. The safety hierarchy is relentless here.
1. Collective protection
This is the absolute priority. Complete enclosures with interlock systems are the best thing you can do. Opening doors during operation immediately turns off the laser. If complete enclosure is not possible (e.g., when welding large structures), controlled zones are created, fenced off with special laser curtains, with light signaling and entrance interlocks. This is supplemented by the mentioned ventilation and filtration system, which is an integral part of a safe workstation.
The highest level of safety and repeatability is provided by fully integrated systems. An excellent example of such a solution, where all collective protection measures are factory-implemented, is a ready-to-work robotic station. Check: Fanuc 5.0 Turnkey welding robot.
2. Individual protection
The use of personal protective equipment is necessary where it's impossible to 100% isolate the hazard. Protective glasses are crucial. They must be certified (PN-EN 207 standard) and selected specifically for the wavelength and power of the given laser. An ordinary welding helmet or anti-splash glasses provide no protection against laser radiation. Special caution must be observed, and when working with an open beam, flame-resistant clothing and gloves are also necessary.
3. Work organization
Even the best equipment won't work without conscious people. Every company using high-power lasers must appoint a Laser Safety Officer (LSO). This is the person responsible for ensuring that an occupational risk assessment is carried out, and based on it, appropriate protective measures are selected and training is conducted. Every operator must undergo specialized OHS training. The workstation must be clearly marked, and emergency procedures practiced.
Safety when using lasers - legal acts, standards and regulations
Laser safety is precisely regulated in appropriate legal acts.
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Directive 2006/25/EC – the EU foundation that imposes on the employer the obligation to assess risks related to direct exposure to optical radiation and ensure that employee exposure does not exceed limit values, i.e., maximum permissible exposure (MPE), consistent with adopted hazard assessment criteria.
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PN-EN 60825-1:2014-11 – the most important technical standard. It classifies lasers (from safe Class 1 to worst Class 4, where the highest level of laser radiation occurs and which produce dangerous diffuse reflections), determines requirements for marking and safeguards that the manufacturer must meet.
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PN-EN 207 and PN-EN 208 – standards determining requirements for glasses and goggles protecting against laser radiation in a specific wavelength range.
Summary
Is laser radiation harmful? Yes, if you use this technology without recommended safeguards. Is laser technology safe in industrial implementation? Absolutely yes, provided you follow safety rules, because uncontrolled exposure can have harmful effects. Modern, enclosed laser devices, supported by solid procedures and safety culture, minimize risk almost to zero, and accidents occur less frequently than with mechanical machines.
You now know what to pay attention to in order to ensure complete laser work safety. If you want to select technology perfectly matched to your needs, schedule a free consultation with our expert. We'll help you go through this process step by step, so you can be sure that your investment will be 100% safe from the very beginning.