The optimization capabilities in design-expert software were used to optimise the keyhole parameters (i.e. maximize penetration (P) and minimise the heat input, width of welded zone, (W) and width of heat affected zone (WHAZ)) in CW CO2 laser butt-welding of medium carbon steel. The previous developed mathematical models to predict the keyhole parameters in terms of the process factors namely; laser power (LP), welding speed (S) and focused position (F) were used to optimize the welding process. The goal was to set the process factors at optimum values to reach the desirable weld bead quality and to increase the production rate. Numerical and graphical optimization techniques were used. In fact, two optimization criteria were taken into account. In this investigation optimal solutions were found that would improve the weld quality, increase the productivity and minimize the total operation cost. In addition to that, superimposing the contours for the various response surfaces produced overlay plots.