The most common myths in fiber laser maintenance

fiber laser

Fiber lasers in modern industry

High-powered fiber lasers have a wide range of applications across industries. As new uses emerge, more manufacturers recognize industrial fiber laser systems as reliable and cost-effective.

Like other industrial tools, fiber laser technology has advanced significantly over the past decades. However, some myths about their operation and maintenance still exist. Here are the most common ones.

Common myths in fiber laser maintenance

Myth 1: Fiber lasers don’t require much monitoring

The first myth is that fiber lasers require little monitoring. CO2 lasers were originally used as industrial tools due to low operating costs and simple maintenance. Fiber lasers changed the industry by offering improved beam quality and lower maintenance. Despite this, fiber laser modules still contain physical components that can fail over time, especially in harsh industrial environments. Periodic maintenance is therefore necessary to maintain efficiency and control operational costs.

Myth 2: Increasing power fixes performance issues

Another myth is that raising the power solves performance issues. Performance loss usually stems from factors such as thermal effects caused by aged, damaged, or contaminated optics, reducing power density. Modern fiber laser measurement tools help diagnose and optimize these systems.

Myth 3: Measurements are not costly or slow

A third myth is that measurements are costly and slow. Advances in optical components and computing have made fiber laser measurement tools smaller, faster, and more affordable. They can now be embedded in other systems, and fiber lasers are easier to operate in harsh production environments.

Myth 4: Performance management requires proper measurement

Another myth is that performance can be managed without measurement. Without key performance data, operators risk inconsistencies and scrapped parts. Regular measurements ensure consistent performance, lower power consumption, and higher profitability.

Myth 5: Modern measurements outperform old technologies

The fifth myth is that old measurement technologies are sufficient. Relying on outdated tools limits data collection. Modern fiber laser measurement products provide more detailed performance analysis for short or long-term use.

In conclusion, collecting more performance data improves industrial processes.

Fiber laser development for fast materials processing

Fiber laser

Experimental development of high-power fiber lasers

Specialists in fiber laser technology from Germany and Israel are conducting experiments with a newly developed fiber laser for industrial use. The system is based on the Coherent Beam Combining (CBC) method, which is still relatively new for high-power fiber lasers.

According to the researchers, the 13-kilowatt fiber laser can rapidly create various energy distribution patterns during operation, allowing precise and efficient processing of demanding materials. The goal is to make this innovative technology available to companies and manufacturers worldwide. The team expects these experiments to open new laser applications, making a significant contribution to fields such as medical technology and aerospace.

Innovations in laser beam shaping

Dynamic beam shaping for additive manufacturing

The research team is now studying laser beam shaping accelerated by a factor of 1000, applied for the first time in additive manufacturing. They use the Coherent Beam Combining method, where the Dynamic Beam Laser merges many individual beams into one powerful, high-quality beam. Tiny phase shifts in the individual beams allow the fiber laser to quickly generate different energy distribution patterns.

New energy patterns for improved processing

The new fiber laser system can form specific energy patterns on workpieces, such as a horseshoe or a ring. In contrast, conventional fiber lasers concentrate most of the energy in the beam center. Previously, such shaping was possible only with beam-deflecting optics or oscillating mirrors, which required milliseconds to change patterns. The new fiber laser performs these adjustments 1000 times faster — within microseconds — enabling its use in metal additive manufacturing.

Applications in additive manufacturing and industry

Metal 3D printing

The researchers aim to develop a modern fiber laser system for additive manufacturing of titanium and aluminum alloys, widely used in aerospace components and implants. They plan to apply dynamic laser beam shaping to eliminate defects and improve 3D printing quality. Novel beam shapes could also help overcome challenges with crack-sensitive materials.

Potential industrial impact

The experiments will show whether the new fiber laser system can be used for metal additive manufacturing. The proven advantages in quality and speed already make this technology promising for metalworking, electromobility, and aerospace industries.