New Welding Methods for Toyota/Lexus

If you have been working on any Toyota/Lexus vehicles recently, you may have noticed a new type of attachment method. This new attachment method is known as laser screw welds. How is a Toyota/Lexus vehicle laser screw welds repaired? Let’s take a look.

Toyota/Lexus has utilized this new welding technique for production, due to its speed, and the ultra-high-strength steel (UHSS) structures being produced. If you want to see just how fast the process is check out this video Laser Screw Welding .

There are a few ways to identify laser screw welds; for starters you should be able to spot them on the pinchweld. Laser screw welds are about half the size of a traditional spot weld. They also protrude outward, rather than the indent of traditional spot welds. You can also identify their location by using the Toyota/Lexus body repair manual. In the manual laser screw welds are identified by Xs. The 2016 Prius is an example of laser screw weld usage.

Due to the complex equipment needed for creating laser screw welds, they cannot be duplicated in the collision repair setting. To replace laser screw welds Toyota/Lexus recommends squeeze-type resistance spot welding (STRSW), as the preferred method. When STRSW arms cannot reach, traditional GMA plug welds may be an option.

If you are welding on ultra-high-strength steel (UHSS) you must perform a test to see if plug welds can be used. In the test, practice welds are made, using the correct weld spacing, to determine if the heat-affected zones (HAZ) overlap. If the HAZ overlaps plug welds cannot be used.

This publication from Toyota Collision Repair and Refinish Training (CRR Training) has more detailed information on replacing laser screw welds. Collision repair information is also available on You will be able to find out if the vehicle you are repairing utilizes laser screw welds, also, where the welds are located.

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