Customized extensions for laser projection in industrial applications

SL Laser develops high-performance accessories for laser projection in production and assembly, tailored to real-world requirements in industry, composite manufacturing, mechanical engineering and CNC applications. The goal is seamless integration into existing processes while sustainably increasing efficiency and process reliability.

Accessory solutions for maximum productivity

Mobile Workstation – flexible laser projection without fixed installation
Ideal for changing work environments. This mobile unit combines a laser projector, industrial PC and height-adjustable swivel arm on a mobile cart. Perfect for applications where components cannot be processed in a fixed position.

Certification Tool – verified precision for the highest quality standards
Especially in demanding industries such as aerospace or automotive, this tool enables precise measurement and documentation of projection accuracy.

Motorized Tilting Fixture – precise alignment at the push of a button
For large components or complex systems, the stepless angle adjustment ensures maximum accuracy and ease of use.

Rail Systems – laser projection for large production areas
Ceiling-mounted systems with movable projectors allow flexible use across extended workspaces, for example in concrete production or series manufacturing.

Industrial PCs and modular components
High-performance hardware ensures stable operation and enables integration into automated production lines and CNC control systems.

Your advantages with SL Laser accessories

• Increased process reliability through precise projection and documentation
• Greater flexibility thanks to mobile and modular systems
• Optimized production workflows through seamless integration
• Scalable solutions for growing production requirements

Laser projection taken further

With SL Laser accessories, you can expand your laser projection systems in a targeted way and adapt them precisely to your production environment. From mobile applications to full integration into complex manufacturing systems, you benefit from solutions that sustainably improve efficiency, quality and competitiveness.

SL Laser – tailored solutions for precise production processes.

Laser projection as the foundation of reliable composite manufacturing

Precision and repeatability are critical in fiber composite production. SL Laser projectors display CAD data, contours and positioning aids directly onto components or tools, eliminating manual marking and templates.

Computer-controlled projection standardizes workflows, reduces error sources and ensures traceable, reproducible processes. Especially for complex geometries and demanding production environments, this creates a significant competitive advantage.

Real-time monitoring in vacuum bagging

A key focus at JEC 2026 is the integration of laser projection with intelligent process control. In vacuum bagging applications, the countdown begins only after a predefined minimum vacuum level has been reached. The current vacuum status is continuously displayed as a percentage.

If the required value is not achieved, the timer remains inactive. Status values are transmitted continuously, for example in the format VACUUM 80

An optional pause function allows controlled interruption of the process. This approach replaces purely time-based control with real physical parameters, increasing reliability, reducing scrap and improving documentation.

Integration into modern production environments

SL Laser systems integrate seamlessly into existing CAD and manufacturing environments. Sensors, software and projection technology work together to enable structured and transparent production processes.

For multi-layer composite manufacturing in particular, the combination of 3D laser projection and monitoring ensures precise positioning and reliable quality assurance.

Invitation to JEC World 2026

At JEC World 2026, SL Laser will demonstrate how laser projection and process monitoring increase efficiency and reliability in composite production.

Visitors will gain insight into:

• 3D laser projection for layup applications
• Integration of vacuum countdown systems
• Sensor-based process control
• Software solutions for reproducible manufacturing processes

SL Laser – Process reliability through precise laser projection.

More information:
www.sl-laser.com

Pioneer in Laser Projection

Since the early days of this technology, SL Laser has been a pioneer in laser projection, providing essential tools for production and assembly. With thousands of installed laser systems worldwide, SL Laser projectors significantly enhance workflows across various industries.

Efficient Template Projection and Fast Workflow

The use of laser projectors for projecting edges, drill holes, and contours has become standard in many industrial and craft businesses. Instead of the labor-intensive process of preparing expensive templates, the ProDirector 7 projects all necessary templates directly onto the workpiece or work table at the push of a button.
This device can effortlessly switch to the next work step or layer, allowing for rapid, precise, and safe task continuation. Typical work time reductions of 25% or more are combined with precision that enhances product quality and lowers error rates within companies.

Simplified Quality Management

The tedious work of measuring and transferring plans is eliminated, reducing the chance of mistakes. Many quality management tasks are simplified as individual elements can be highlighted step by step for easy verification.

Applications in Various Industries

This time-saving approach means positions no longer need to be identified and re-measured, and sampling inspections of complex components are significantly accelerated. In most cases, the data required for the laser projector is easily converted from CAD software and transmitted directly to the projector.

In large facilities, such as woodworking in furniture production, these systems serve as setup aids for CNC milling machines, keeping all suction cups intact while perfectly positioning workpieces.

In other sectors like timber frame construction and laminated beam processing, components are no longer manually aligned. Instead, they are projected directly from CAD data, enabling quick and reliable positioning of nails, slats, or laminated beds.

This method eliminates the need for templates and reduces the need for extensive corrections, resulting in fewer errors, less material waste, and significantly increased work speed.

Laser Projectors in Aerospace

In aerospace manufacturing, a network of laser projectors is often employed, interconnected for enhanced efficiency. Many companies also use a system that allows the laser projector to move along a ceiling-mounted rail, with positions pre-saved to enable seamless transitions between work steps.

This technology considerably boosts employee motivation. With an accuracy of 0.35 millimeters, satisfactory precision is achieved even in helicopter cockpit assembly, where numerous switches must be installed precisely.

Software and 3D Applications

The next evolution in laser projector use is sophisticated software, especially for complex components and prototypes. SL Laser has developed software like SL3D for 3D composite applications.

SL3D allows seamless interaction with 3D data and multiple projectors, importing 3D CAD data from common formats (STEP, IGES, DXF, XML, PLY) and displaying up to four views simultaneously.

Besides graphical images and projections, PDF or JPG files describing the work process can also be displayed, with the appropriate projector automatically selected for each processed layer.

Seamless Integration and Training

SL Laser consistently ensures its laser projectors integrate smoothly into existing workflows and processes, applying the same philosophy to user software and customer training. This approach has allowed SL Laser to successfully launch products globally since the 1990s.

Comprehensive Product Range

Positioning lasers with line, cross, and circular optics form an essential product line alongside laser projectors and measuring systems, becoming indispensable in craft and industrial production.

A line laser from SL Laser guarantees maximum precision, robustness, and impressive range, accelerating and simplifying positioning tasks for tools and components.

Green lasers are typically preferred for better visibility, but red lasers may perform better under certain lighting conditions.

With a positioning laser from SL Laser, you invest in a durable, precision instrument optimized over decades. Thousands of industrial and craft businesses worldwide rely on SL Laser systems.

For more information, contact SL Laser, your reliable partner for laser applications for over 35 years.

With decades of experience, SL Laser’s laser projection systems support a broad range of industries, including automotive manufacturing, prefabrication, timber construction, and concrete element production. These systems are instrumental for accurate alignment, positioning, and visualization tasks across complex project workflows.

SL Laser’s offerings include innovative options to accommodate challenging spatial configurations and budget considerations. While standard solutions often suffice, customer-specific adaptations are a core component of SL Laser’s approach, allowing for cost-effective and space-efficient integration. One notable development is utilizing independent laser projection units customized to individual project requirements, enabling flexible and scalable operations.

A key advantage of SL Laser’s system architecture is utilizing rail-based setups that assist simultaneous work on multiple tools of varying sizes. This configuration allows operators to use two trolleys on the same large component, with each trolley functioning independently behind the scenes. Such modularity permits predefined work positions, minimizes needing multiple laser heads, and reduces overall investment costs. Besides, equipped with large screens and user-friendly interfaces, these systems deliver important real-time information, such as ply books, JPEG and PDF documentation, and operational remarks, to operators directly at the work site.

In advanced automation and quality control, SL Laser has introduced solutions integrating sensors and software for real-time process monitoring. For instance, the company has developed a vacuum sensor-based compaction tool used in composite manufacturing. This system continuously displays the vacuum level in percentage and manages the process through an integrated countdown, enhancing process reliability and ensuring proper material compaction without relying solely on time-based parameters.

Antonios Alexoudas, General Manager at SL Laser, emphasizes the company’s focus on developing adaptable solutions: “Our systems are designed to meet the specific needs of each project, whether it involves space constraints, cost considerations, or specialized process requirements. Flexibility is fundamental to our innovation process.”

The company’s long-standing commitment to innovation stems from its recognition of the diverse challenges faced by modern production and construction environments. Customers often operate within complex spatial limitations or tight schedules, necessitating personalized solutions that maximize functionality without incurring unnecessary costs. Through modular system configurations, such as rail-mounted laser projections and portable units, SL Laser enables clients to optimize their workflows, improve accuracy, and reduce downtime.

In addition to hardware solutions, SL Laser offers comprehensive software support, exemplified by its SL3D platform. This software provides real-time visualization and process monitoring, integrating data from sensors and project files to enhance operational control. The system’s compatibility with various file formats and its ability to display detailed instructions optimize project execution on-site.

SL Laser’s product portfolio also incorporates specialized tools for specific industry segments. For example, in timber frame construction, laser systems assist in positioning prefabricated walls and trusses, ensuring precision and reducing assembly time. Similarly, in concrete manufacturing, laser projection systems assist accurate placement of formwork and reinforcement elements, contributing to higher quality and consistent product dimensions.

The company’s emphasis on innovation and customization is reflected in its approach to customer challenges. Whether a project involves small tools requiring individual laser heads, large tools demanding integrated projection systems, or complex processing parameters like vacuum control, SL Laser develops solutions customized to each scenario. This level of adaptability distinguishes SL Laser as a leader in the laser projection industry.

"Understanding the unique needs of each project allows us to deliver solutions that are both practical and efficient," remarked Mr Alexoudas. "Our goal is to support industries in achieving precision and productivity through technological innovation."

As SL Laser continues to expand its portfolio, the company remains committed to delivering durable, reliable, and flexible laser projection systems. Through ongoing research and development, the organization aims to address emerging industry demands and maintain its position at the forefront of laser technology.

For more information about SL Laser’s products and solutions, please visit the company’s website or contact their technical support team.

Laser projection with SL Laser means saving time, reducing material use, and ensuring maximum accuracy. The SL Assembly Software plays a key role in replacing time-consuming tasks with digital precision for creating physical templates or manually aligning workpieces. This allows streamlined workflows, fewer errors, and significantly reduced production costs, whether in medium-sized workshops or large international enterprises.

Modular Design – Flexible Use

The SL Assembly Software consists of three modules, which can be used as needed:

• Module 1, included with the purchase of a SL Laser ProDirector, is used to optimize projection data. Calibration files can be generated, laser parameters defined, and additional information such as work instructions or plybooks added directly in PDF, image, or text format. This turns technical data into usable guidance for day-to-day operations.
• Module 2 is aimed at companies that want to generate their own projection data from CAD files, such as STEP, IGES, or DXF formats. An integrated drawing mode allows users to extract only the relevant contours for production and edit them as needed. Custom projection sequences can be created and modified. This is ideal for production environments with a high degree of variation.
• Module 3 is specifically designed for handling complex parts with multiple components. The software automatically detects individual elements as clips or brackets and allows users to select the lines they want to project. This enables precise alignment, positioning, and even final quality control through laser-guided projection.

Added Value Through Integration – Proven Worldwide

The SL Assembly Software clearly demonstrates how SL Laser responds to individual customer needs with functional, real-world solutions. Developed in close collaboration with production professionals, it helps establish laser projection as a complete process solution. It shows its strength from data import to visual guidance and documented execution.

The software is used worldwide by companies that demand the highest levels of precision and flexibility – from aircraft manufacturing and the space industry to serial production in mechanical engineering. Combined with SL Laser’s versatile laser projectors, it forms a complete package that pays off quickly and gives users a lasting competitive edge.

With the SL Assembly Software, SL Laser proves: those who view laser projection not just as a tool, but as part of an intelligent, integrated workflow are investing in efficiency, quality and future viability.

Our SL3D software and projectors can manage up to eight independent tools or molds, projecting onto all of them simultaneously. The operator simply selects the mold and the desired ply.

SL3D is primarily used in the composite lay-up process and for projecting fixtures, holders, click bonds, or even wiring during assembly. The same software is also frequently used for part projection before welding. A wide range of features enhance the efficiency and quality of 3D projection, and additional license modules are available for special applications.

A key feature is the automatic calibration system, which ensures high accuracy in the lay-up process and significantly reduces calibration time. The electronic ply book function provides comprehensive quality control documentation, allowing seamless integration into existing production workflows.

Key features include:

• Automatic projector selection: In multi-head systems, the software automatically selects the optimal projector for projecting a line or segment, based on the projector’s position relative to the mold.
• Point reduction/optimization: Reduces the number of points in a ply file to optimize projection speed and minimize flicker, while maintaining necessary accuracy.
• Password-protected operator levels: Scalable security allows access to software features only as assigned by the administrator. For example, standard users cannot modify data.
• Optional biometric authentication: Operator access levels and identity can be verified via fingerprint scanning using a special keyboard.
• Optional barcode scanner: For quick ply information retrieval.

Extended user rights offer advantages such as:

• Granting operators additional permissions for certain functions.
• Options like manual calibration or menu access.
• Allowing operators to confirm specific steps without requiring administrator approval each time.

Process Security for Operators

Additional online guides for production, provided as text or graphical information, are displayed on-screen with the corresponding layer. For example, a drawing or photo can show how to perform a specific step. This information appears either by programmer command or automatically when a layer is selected.

Trolley System Support

• SL3D supports laser rail (trolley) systems, allowing two trolleys to work on the same tool, and then independently on different tools after finishing.
• Work positions can be predefined.
• To simplify operations, SL3D allows the use of multiple monitors for different tools, all managed by a single SL3D software instance. Each workstation has its own screen displaying relevant information.
• Screens can be wall-mounted or freestanding, providing operators with detailed instructions, including PDFs or JPEGs for visual guidance.

Vacuum Bagging Process Feature

• SL3D includes a vacuum bagging countdown protocol for external control.
  • While the countdown is running, SL3D displays the current vacuum status as a percentage.
  • The countdown does not start (display remains gray) until the minimum vacuum value is reached.
  • Once the minimum value is achieved, the countdown begins, and the display turns green.

Precise Laser Projection for Optimal Lay-Up Processes

SL Laser GmbH’s high-precision laser projectors enable the exact projection of complete drawings, outlines, or parts of drawings onto a surface. This gives employees perfect control over the manufacturing process, ensuring the highest accuracy and efficiency. Due to the variability in production processes and materials, each laser system, centered around the ProDirector 7, is individually tailored to the specific requirements of the client. This results in customized solutions for various production needs.

Key Features of the SL3D Software

The SL3D software offers a variety of features that enhance the efficiency and quality of composite processing. A key feature is the automatic calibration system, which ensures the accuracy of the lay-up process and significantly reduces calibration time. Additionally, the electronic playbook function provides comprehensive quality control documentation. The SL3D software supports the import of files from common CAD systems such as CATIA, FiberSIM, and AutoCAD. This flexibility allows for seamless integration into existing production workflows. Other features include the automatic selection of the ideal projector in a multi-head system, point reduction options, and projection optimization. The software also boasts important security features such as password-protected user levels and the ability for user verification via fingerprint scan or barcode scanner.

Exceptional Service and Support

SL Laser GmbH not only offers popular products that have been trusted for decades but also legendary service and support. With specially trained and experienced engineers in Germany, France, and the USA, the company ensures quick and competent onboarding followed by reliable support. This is complemented by appropriate technical equipment. The SLNET diagnostic system allows support personnel to remotely connect to customers‘ PCs to diagnose software and hardware issues and provide remote updates.

Globally accepted solutions for the industry

Combining precise laser projection and versatile SL3D software, SL Laser Systems has been setting significant benchmarks in composite processing for years. The extensively tested and proven features, along with reliable customer service, make SL Laser GmbH one of the world’s preferred partners for leading companies in the aerospace, aviation, and automotive industries.

The laser projection systems are used in numerous industries:

• For aligning welding parts
• In composite workshops
• For positioning fixtures on various tables, also for displaying component contours
• For displaying workpieces for CNC milling machines
• As a visual aid when inserting blanks into tools
• For positioning formwork in concrete plants for prefabricated parts
• In timber frame construction for prefabricated wooden walls and roof trusses

SL Laser is the only manufacturer of laser projectors that offers customized solutions

This makes our offerings particularly in demand, as many customers have production areas that pose a challenge for laser systems.

Whether it’s long truss tables, special prefabricated tables for concrete walls, or glued laminated timber applications: In all these situations, SL Laser offers various options to master the challenge of the special dimensions of the application and work area. Some customers have limited space available. In such cases, we come up with solutions to create enough space between the work area and the installation point for the laser.

To achieve this, SL Laser works closely with the customer to find the best option for them. We inspect the hall or obtain drawings to determine what the area looks like. We create corresponding plans with the placement of the laser heads. We can, for example, arrange the lasers in a row.

It may happen that the work area is 100m long or longer! In such cases, a rail system is used, in which the projector is installed in a carriage or forms a row with a laser from a carriage. The laser can then move automatically on the rails and stop at certain positions to project the drawings onto the work surface. SL Laser also provides special carriages for the laser and the rails. In other cases, we have developed various types of clamps that, for example, allow the laser to be used inside aircraft fuselages.

In some composite workshops, a mobile workstation with the projector is used. This allows, for example, a customer with decentrally positioned satellite panels to appear on-site with this workstation and, after calibration, project the parts for laying or assembly. After completing the work, they can move on to the next location with the workstation or park the vehicle in a parking lot for the next day.

The mobile station can be equipped with a laptop or desktop computer. The system is height-adjustable, and the customer can use it as a single-head or dual-head system for large components. An additional mobile work unit can be added for a large component. These units are connected via cable or Bluetooth. With a swivel mount on the laser head, the best angle for projection can be set.

• for aligning welding components
• for positioning clamping devices on different work tables
• for projecting cutting lines and contours for the layout of metal parts
• for workpiece display for drilling and milling work
• for quick set-up of steel trusses
• for positioning cutting, bending and forming lines
• for pattern generation for the automation of repetitive work

The laser projectors in use

We are reporting here on a company that manufactures vehicles for a payload range between 20 t and 10,000 t and delivers them worldwide. The first laser systems from SL Laser GmbH have been in use at the Memmingen plant since 2006. Before the laser projectors were used, the components were positioned in the traditional way with the help of plans and measuring aids such as tape measures and folding rules. Among other things, this led to long cycle times and the usual measuring errors.

Today, the laser projectors are used at two workstations. At the first, two laser projectors are permanently mounted above a welding table. At the second workstation, a mobile laser is used on a movable trolley, which is used flexibly for larger components. Outlines of components are projected. A PC is used for both workstations, which loads and projects the prepared projection files using the installed SL 3D software.

The projection process

First, the laser must be calibrated. At the fixed laser station, this is done using calibration points that are inserted into the hole grid of the welding table. At the mobile laser station, the laser calibrates itself using calibration points that are attached directly to the component. After calibration, the projector projects the first contour of the add-on part. The sequence is determined by work preparation when the projection file is created or is changed directly at the workstation if necessary. As soon as the projected laser beam is congruent with the component edge, the add-on part is correctly positioned. Remote control is used to switch from Layer to Layer.

To assist the operator, large monitors can display the current work steps or components in enlarged form. The SL3D software allows the screen to be split. In addition to the current contour of the add-on parts, additional work instructions for the worker can be displayed in image or text form, for example.

According to the user, the use of the laser saves 30% to 40% of the working time per axle carrier frame, as a lot of time is needed for measuring without the projection.

Thanks to the laser display, measuring errors and the risk of components being forgotten in the process are eliminated.

The work preparation department creates the projection files in advance

The relevant employee uploads the CAD drawing and then defines the lines that are to be projected. The contour of the add-on parts is usually divided into individual layers, which are later switched through by remote control. Labels or position numbers can also be projected. The target points for the orientation of the laser are defined on the table’s perforated grid system or, in the case of the mobile laser station, directly on the component.

The introduction of the system by SL Laser

For new customers, SL-Laser prepares a projection file together with the customer for an initial demonstration of the laser projectors. The work preparation department recognizes and learns the procedure and can organize itself accordingly. The 3D data from the component in STEP or IGES format serves as the basis. As soon as the customer puts the system into operation himself after the first test runs, SL Laser is available to provide advice by telephone or via remote connection.