Industrial laser safety: how can a regulatory obligation be turned into a genuine competitive advantage?

Welding, cutting, additive manufacturing, cleaning or stripping by laser: laser processes are experiencing spectacular growth in industry. But behind the productivity gains lies an often underestimated reality: controlling laser risk is becoming a strategic issue for manufacturers. Risk analysis, regulatory compliance, choice of protective measures, operator training… these are all areas where expertise now makes all the difference.

Lasers are taking hold in industry… and so are companies’ responsibilities

Laser applications continue to expand. Once reserved for a handful of cutting-edge sectors, high-power lasers are now found in aerospace, automotive, nuclear, metallurgy, additive manufacturing and maintenance activities.
The spectacular development of handheld laser cleaning and stripping systems has also profoundly changed practices. This equipment allows work to be carried out directly on site, with great flexibility… but it also makes risk control far more complex than within a robotic cell.
Among companies, a misconception persists: buying a CE-certified machine is enough to guarantee operator safety.
The reality is quite different.
Machine compliance never exempts the employer from carrying out a risk analysis of its installation, defining appropriate preventive measures and training users.
This is precisely where IREPA LASER’s added value lies today.

Unique expertise, built at the heart of laser technologies

For more than forty years, IREPA LASER has supported manufacturers in developing and securing their laser applications.
This dual expertise is relatively rare.
Because its teams are involved in developing innovative laser processes while also carrying out safety assessments, they have a thorough understanding of users’ industrial constraints.
This global vision goes far beyond a simple reading of regulatory texts.
Every recommendation is designed to be technically relevant, compliant with regulations and compatible with production constraints.

The IREPA LASER expert’s view

“A laser installation that is perfectly compliant on paper can become dangerous after a simple process modification, a change of part or a maintenance operation. Laser safety must be seen as a living process that evolves with the installation.”

Laser accidents rarely happen where you expect them

Contrary to popular belief, accidents do not generally occur during normal production.
They mainly occur during:

• maintenance operations;
• optical adjustments;
• set-up trials;
• alignment operations;
• work carried out with guards open.

In more than two thirds of serious accidents recorded internationally, safety devices had been deliberately disabled to make adjustments easier.
The consequences can be dramatic.
An exposure of just a few milliseconds can sometimes cause an irreversible retinal burn.
With Class 4 lasers, the risks also include skin burns, fires, process fumes and stray reflections from metal surfaces.

A risk analysis cannot be improvised

Every laser installation is different.
Two machines using exactly the same laser source may require completely different protective measures.
Why?
Because the risk depends in particular on:

• the wavelength;
• the emission mode;
• the power;
• the beam divergence;
• the materials processed;
• the geometry of the parts;
• the potential for reflections;
• the operating procedures;
• the planned maintenance operations.

IREPA LASER’s experts carry out comprehensive risk analyses, enabling in particular:

• determination of Nominal Ocular Hazard Zones (ZNRO)
• calculation of safety distances
• selection of suitable collective protective measures
• verification of the compliance of EN 207 eyewear
• validation of laser screens, curtains and guards
• analysis of interlocking systems (interlocks)
• proposal of the necessary technical improvements

The aim is simple: to build a genuinely safe installation without penalising production.

Training: the first piece of protective equipment

Even the best collective protective measures can never replace competent staff.
At IREPA LASER, training has for many years been a key focus of prevention.
The offer covers all of manufacturers’ needs.

Laser Safety Informed Person (Level 1): acquire the fundamentals of laser safety
This training is mainly aimed at operators who use laser equipment but are not exposed to radiation exceeding Class 2.
It helps participants understand the hazards of laser radiation, identify risk situations and apply good preventive practice.

Person Exposed to Laser Risks (Level 2): master the day-to-day use of industrial lasers / training accredited by CoNSOL (Commission Nationale de Sécurité Optique et Laser of the Fédération PHOTONICS France)
Intended for regular users of Class 3R, 3B and 4 lasers, this training covers regulatory aspects, protective measures and operating procedures in depth.
Participants learn to identify safety deviations, respond to unusual situations and work safely in their industrial environment.

Laser Safety Officer (Level 3): master the day-to-day use of industrial lasers / training accredited by CoNSOL (Commission Nationale de Sécurité Optique et Laser of the Fédération PHOTONICS France)
Intended for regular users of Class 3R, 3B and 4 lasers, this training covers regulatory aspects, protective measures and operating procedures in depth.
Participants learn to identify safety deviations, respond to unusual situations and work safely in their industrial environment.

Competent Person in Laser Safety (Level 3+): training Laser Risk Managers / training accredited by CoNSOL (Commission Nationale de Sécurité Optique et Laser of the Fédération PHOTONICS France)
The Competent Person in Laser Safety (PCSL) training is now the benchmark for those required to act as Laser Risk Manager.
Over several days, participants develop genuine expertise enabling them to:

• carry out risk analyses;
• understand regulatory requirements;
• define appropriate protective measures;
• calculate exposures and safety distances;
• advise their management on new laser projects.

This training is now attended by many industrial companies wishing to bring this strategic competence in-house.

The IREPA LASER expert’s view

“Training a Laser Safety Officer is not just about passing on regulatory knowledge. Our aim is to develop genuine analytical skills so that every trainee can make the right decisions in the situations they encounter in their company.”

The laser safety audit: taking a step back from your installations

Many companies today operate installations commissioned several years ago.
Since then, processes have evolved.
Equipment has been moved.
Modifications have been made.
Teams have changed.
All of these factors can gradually lead to safety deviations.
The audits carried out by IREPA LASER provide an objective view of the situation.
They cover in particular:

• regulatory compliance;
• existing risk analyses;
• collective protective measures;
• interlocking devices;
• personal protective equipment;
• signage;
• operating procedures;
• maintenance operations;
• technical documentation;
• user competencies.

At the end of the assignment, a report prioritises the key actions needed to improve safety levels over the long term.

Supporting manufacturers from the design stage

Experience shows that it is much simpler — and much less costly — to build safety into an installation from the design stage than to correct non-conformities once the machine is in production.
That is why IREPA LASER regularly works with:

• laser machine manufacturers;
• integrators;
• engineering firms;
• large industrial groups;
• SMEs developing their first laser processes.

This support may cover the definition of protective measures, the choice of enclosure materials, interlock validation, safety calculations and the drafting of operating procedures.
The aim is to integrate safety as a natural component of the industrial project.

Customer testimonial

“When we acquired our first laser cleaning cell, we thought that the ‘turnkey’ machine met all regulatory requirements. IREPA LASER’s support enabled us to identify several critical points relating to workstation organisation, peripheral guarding and operator training. Today, our installation is compliant and our teams work with far greater peace of mind.”
HSE Manager – Industrial group in the aerospace sector

Much more than a training provider

While IREPA LASER is recognised as one of France’s leading laser safety training providers, its expertise goes far beyond that.
Its teams work daily across the entire life cycle of installations:

• regulatory support;
• technical assistance;
• safety expertise;
• risk analyses;
• audits;
• validation of protective measures;
• operator training;
• training of Laser Risk Managers;
• support for new industrial projects.

This comprehensive approach ensures complete consistency between regulatory requirements, technical constraints and production objectives.

Anticipating today to secure tomorrow’s industry

Laser technologies will continue to develop in the coming years.
Power levels will increase.
Applications will diversify.
Equipment will become ever more mobile.
In this context, laser safety can no longer be regarded as a mere regulatory obligation.
It will become a genuine driver of competitiveness, quality and industrial performance.
Drawing on its scientific expertise, its knowledge of industrial processes and its field experience, IREPA LASER supports companies through this change so that they can fully exploit the potential of laser technologies, in complete safety.

Make laser safety a lever for performance

Would you like to check the compliance of your laser installations, carry out a risk analysis, train your teams or receive support for a new industrial project?

IREPA LASER’s experts support you at every stage, from the design of your installations through to their operation, balancing regulatory requirements, operator safety and industrial performance.

Contact IREPA LASER to discuss your needs and benefit from tailored support. Together, let’s build a laser safety strategy suited to your processes, your constraints and your production objectives.