Success Story: Jon Koehler

A self-taught artist and sculptor harnesses laser welding to push the boundaries of metal art. 

What’s a Success Story?

There are a lot of reasons why our customers invest in LightWELD: it might solve a specific problem for them, or help them be more productive, or they might just be excited by the technology. Whatever the reason, we love talking to them and learning about their businesses.

Our success stories are a closer look at some of our customers, what they’re working on, and how LightWELD has helped them find success. We hope that their stories can help give you a better idea of how the industry is using and benefiting from LightWELD.

About the Artist

Jon Koehler’s journey in metalworking began at his father’s boatyard in San Diego, CA. Surrounded by docks and yachts needing custom outfitting year-round, Koehler honed his craft working with aluminum, bronze, and stainless steel. From rod holders to tuna towers, he took pride in creating what he calls the “jewelry” of the yacht industry.

By the 1990s, his expertise shifted to high-performance automobiles. At an exotic sports car dealership Koehler transformed factory Porsches, Lamborghinis, and Maseratis into track-ready race cars, refining his fabrication skills even further in the process. However, his passion eventually led him back to the boatyard, where he took on ambitious projects for mega yachts that demanded artistry and precision.

Eventually, Koehler sought a new outlet for his creativity. Turning to sculpture, he found freedom in designing without constraints, drawing inspiration from nature’s forms and movement. “I just wanted to make something that hasn’t been made before,” he says. “I’m kind of obsessed with shapes and colors, and that’s the root of this whole art thing.”

Today, Koehler has more than two decades of experience producing large, and often complex, public sculptures.

Check out Jon Koehler’s sculptures and learn more about his work here.

The Challenge

Koehler has pioneered a distinctive sculpting technique by layering two sheets of flat stock metal, welding them together, and then pressurizing them until the desired shape takes form. According to Koehler, it is not uncommon for parts to go through several rounds of pressurization before the right form is achieved.

Getting the pressure just right to achieve the perfect “wrinkles” in some pieces can be a challenge.

However, TIG welding posed significant challenges. Working with 18- and 20-gauge materials, excessive heat often led to warping. “Because TIG is slow, it looks like a potato chip by the time you finish,” Koehler explains. “That initial warpage just causes problems for the end result.”

Furthermore, each pressurization cycle risks rupturing the base material or the weld seam, requiring quick repairs. Koehler needed a welding solution that minimized heat input while maintaining strong, clean welds that could withstand extreme pressure.

The Solution

With TIG welding not an option, Jon turned to laser welding and became an early adopter of LightWELD technology. Even without prior laser welding experience, he quickly eased into using the machine. Unlike traditional welding techniques, the low heat input of laser welding allowed him to weld thin materials quickly with virtually no warping.

Clean welds are particularly important in the world of metal art and sculpture.

One of the biggest advantages Koehler found was the ease of use. According to Koehler, traditional welding required constant adjustments to avoid over- or under-penetration, making the process stressful and time-consuming. With LightWELD, the wire feed attachment helped Koehler maintain a consistent welding rate, allowing him to focus more on precise weld placement.

Beyond performance, Koehler also valued the support he received from IPG Photonics. “I’m so thankful I didn’t buy a laser welder from overseas — who am I going to call if I run into problems?” he says. “IPG had the service to back up their machines. You guys were there to answer questions and keep me working, and that’s a big deal for anybody investing in a machine like this.”

Finding the perfect balance between stillness and fluidity, Koehler works meticulously to create sculptures that embody the forms and forces of nature. His work has been exhibited around the United States in galleries and in numerous public commissions.