Laser Safety in 2026: What Industry Can Learn from the DOE Laser Safety Officer Workshop
- Melody
- 2 days ago
- 5 min read
As industrial lasers become more powerful, automated, and widespread, laser safety programs have to evolve with them.
That message was reinforced at the 2026 Department of Energy Laser Safety Officer (LSO) Workshop, hosted by Lawrence Livermore National Laboratory (LLNL). Laser Safety Officers and health and safety professionals gathered to exchange lessons, strengthen best practices, and discuss the changing responsibilities involved in managing laser hazards.
For manufacturers and facilities operating Class 3B and Class 4 lasers, the broader message is important: effective laser safety depends on identifying risks before they become incidents and building safeguards directly into the laser system and work environment.
Near Misses Should Be Treated as Warning Signs
One of the most important themes highlighted by LLNL was the relationship between near misses and serious incidents.
LLNL Lead Laser Safety Officer Jamie King told workshop participants:
“Near misses are the result of not paying attention to the details, and accidents are the result of not paying attention to the near misses.”
That principle applies directly to industrial laser operations.
A door that occasionally fails to interlock, an operator who bypasses a procedure, a damaged barrier, an improperly positioned curtain, or an unexpected reflection may not immediately result in an injury.
But each can indicate a weakness in the laser safety system.
Organizations should investigate these warning signs before they develop into more serious problems.
Engineering Controls Reduce Dependence on Human Behavior
Training, procedures, signage, and personal protective equipment all play important roles in a laser safety program.
However, one of the most effective ways to reduce exposure risk is to prevent personnel from accessing hazardous laser radiation in the first place.
That is where engineering controls become critical.
Depending on the application, these controls can include:
Laser safety enclosures
Laser blocking barriers and curtains
Safety interlocks
Interlocked access doors
Laser safety windows
Warning lights and illuminated signs
Emergency stop systems
Beam containment
Safety control systems
A properly designed system creates multiple layers of protection between personnel and hazardous laser energy.
For a high-powered industrial laser, the goal should be to make safe operation part of the equipment's design—not something that depends entirely on an operator remembering every step of a procedure.
Industrial Laser Applications Are Changing
Laser technology continues to expand throughout modern manufacturing.
High-power fiber lasers are now routinely used for cutting, welding, cleaning, additive manufacturing, robotic processing, and other applications.
Handheld laser welding has also introduced powerful Class 4 laser systems into environments where traditional industrial laser cells may not previously have existed.
Automation creates another challenge.
Robots and motion systems can move laser processing equipment through large working envelopes, potentially creating reflection and exposure scenarios that must be considered during the design of the laser safety enclosure.
As applications change, organizations should periodically ask:
Does our existing laser safety system still match the way we are actually using the laser?
The Laser Safety Officer's Role Is Becoming More Important
The DOE workshop also highlighted the evolving responsibilities of Laser Safety Officers.
For industrial facilities, an LSO may be responsible for evaluating hazards, establishing controlled areas, reviewing protective equipment, overseeing procedures, supporting employee training, and helping determine whether appropriate engineering controls are in place.
But laser safety shouldn't exist only on paper.
The most effective programs connect the LSO with engineering, maintenance, production, environmental health and safety teams, equipment manufacturers, and system integrators.
When those groups work together early in a project, hazards can often be addressed during the design stage rather than through expensive modifications after equipment has already been installed.
Designing a Laser Controlled Area
For Class 4 industrial laser applications, creating an appropriate controlled environment can require much more than simply installing a barrier around the equipment.
A complete assessment may need to consider:
Direct beam hazards: Personnel should not be able to enter areas where they could be exposed to hazardous laser radiation.
Reflections: Metal components and tooling can create specular or diffuse reflections that must be considered when determining containment requirements.
Access points: Doors and other entry points may require interlocks tied to the laser safety control system.
Viewing requirements: Operators may need appropriately rated laser safety windows or camera systems to observe the process.
Warning systems: Illuminated laser warning signs and status indicators can communicate whether a laser is enabled or operating.
Maintenance activities: A system that is safe during normal production may create different hazards when panels are removed or technicians perform alignment and service work.
Evaluating the complete operating environment is therefore essential.
Safety and Productivity Don't Have to Compete
A common misconception is that additional safety systems automatically make production more difficult.
Well-designed engineering controls can do the opposite.
A properly engineered laser enclosure and interlock system can allow operators to work confidently around automated laser equipment while minimizing unnecessary interruptions to production.
Modular barriers and enclosures can also provide flexibility when production layouts change or new equipment is installed.
The objective is not simply to place walls around a laser.
It is to create a safety system that works with the manufacturing process.
What Manufacturers Should Review in 2026
The DOE workshop is a useful reminder for organizations using industrial lasers to periodically review their own programs.
Consider asking:
Have there been any laser-related near misses?
Have operators reported unexpected reflections or other hazards?
Are all interlocks functioning correctly?
Have production processes changed since the original risk assessment?
Has laser power or equipment configuration changed?
Are barriers and enclosures appropriate for the laser wavelength and power?
Are laser safety windows properly selected?
Are warning signs and indicators clearly visible?
Are maintenance and service procedures addressed?
Does the Laser Safety Officer have the resources needed to manage the program effectively?
If the answer to any of these questions raises concerns, it may be time for a laser safety review.
RT Technologies: Engineering Laser Safety Into the Process
At RT Technologies, we help manufacturers, research facilities, integrators, and other organizations create safer environments for industrial laser applications.
Our laser safety solutions can include:
Custom laser safety enclosures
Modular laser barriers
Laser safety curtains
Laser safety windows
Laser safety interlock systems
LED laser warning signs
Access control components
Turn-key laser safety systems
Whether you're installing a new laser, integrating a robotic laser cell, expanding an existing production line, or upgrading an older safety system, addressing hazards during the engineering stage can help reduce risk and simplify long-term operation.
Don't Wait for a Near Miss
The lesson from the 2026 DOE Laser Safety Officer Workshop is relevant far beyond government laboratories.
Laser safety requires continuous attention.
Equipment changes. Production changes. Personnel change. Technology changes.
The safeguards surrounding the laser need to evolve as well.
Planning a new laser installation or reviewing an existing laser-controlled area?
Contact RT Technologies to discuss laser safety enclosures, barriers, curtains, windows, interlock systems, warning signs, and custom-engineered solutions for your application.
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