The growing use of handheld Class 4 laser welding systems raises concerns about operator exposure to reflected and scattered radiation. The purpose of this study is to provide an assessment of the angular distribution and intensity of reflected laser radiation generated during manual welding of structural steel and aluminum alloy in butt and fillet joint configurations. It provides the first angle-resolved and height-resolved experimental characterization of reflected radiation in handheld welding, integrating material reflectivity, joint geometry, and observer position – parameters rarely examined together. Radiation intensity was measured at multiple angles, distances, and heights – including helmet-visor level – under controlled laboratory conditions, using identical welding parameters for both materials. Aluminum, with near-infrared reflectance of ≈75–78% compared with ≈14% for steel, produced broader and more persistent reflection fields. For butt joints, mean maximum intensities were comparable (≈1912 ru for steel and ≈2049 ru for aluminum), but probe orientation and joint type strongly modulated exposure: lateral probe positions yielded ≈2.2-fold higher peak intensities than the forward direction for aluminum and more than fourfold higher for steel, while fillet joints increased the mean maximum intensity for steel by ≈109% relative to butt joints (3997 vs 1912 ru). The most hazardous conditions occurred within 10–15 cm of the weld and at probe angles between 30° and 70°, where both materials generated peak intensities above 1.5×10⁴ ru, including at eye level (156 cm), highlighting a substantial risk of ocular overexposure during handheld laser welding. Helmet-level measurements confirmed attenuation of direct radiation. These findings show that effective protection requires PPE with high-optical-density filters, lateral shielding, and an optimized workstation layout, especially when welding reflective materials or working with fillet geometries. Material reflectivity and joint type strongly influence hazard-zone formation, with aluminum and fillet joints presenting the highest risks. Task-specific protective strategies are therefore essential to ensure compliance with exposure limits and maintain operator safety.