Month: September 2025

Overview of fiber laser welding

The fiber laser welding technology keeps expanding as a promising method with advancements in weld quality, dependability, and efficiency. Most fiber laser welding applications are regarded as autogenous, which means the weld is created entirely by melting parts of the base metal, and no additional filler wire or powder is applied.

Applications and need for filler material

Welding applications of a laser beam are almost always autogenous for a huge variety of materials. There are specific materials and challenging applications of laser systems that need the use of filler material in the welding process, resulting in great improvements.

Advantages of fiber laser welding with filler material

The improved fiber laser system provides better joint fit-up tolerance, avoiding solidification cracking during the welding process. The laser system welding changes the chemical composition or the microstructure of the weld metal to obtain suitable mechanical properties, as well as improves the weld profile.

Types of filler material

It is possible to use powder or wire filler material during laser beam welding. Most industrial laser system applications are based on wire use. The main reason for its use is regarded as low cost because generally, powder feedstock is more expensive than wire for most materials.

Factors affecting quality and process

Fiber laser welding with filler wire depends on several conditions that define quality, process speed, and cost. For instance, “the wire feed rate is dependent on welding speed, the cross-sectional area of the gap between the joint face and cross-sectional area of the filler wire.” The application of filler wire in a laser system usually leads to a 10-20% reduction in welding speed, for a given laser beam power, to compensate for the fiber laser energy that has to be used to melt the wire.

Laser beam and filler wire interaction

Laser beam-filler wire interaction also plays a crucial role. The short length of the wire interferes with the wire from being melted at the initial part of the bead; therefore, the laser beam directly leads to the material being melted. The long length of wire, in turn, causes the extended wire end to be pressed against the plate surface.

Importance of focused spot size

It is necessary to pay careful attention to the focused spot size: it should be close to the filler wire diameter because a small spot size of the fiber laser system compared to the wire diameter results in welds with porosity because the filler wire has not melted properly.

Applications and effectiveness

Finally, the fiber laser technology has been tested and demonstrated that fiber laser welding, applying filler wire, provides effective in producing high-quality, robust welds with improved fit-up, reduced weld cracking, and better weld profile. It is possible to use fiber laser systems in a wide range of applications, such as aerospace, automotive, and many industrial fabricating applications.

Innovative fiber laser technology in medicine

A company-manufacturer of medical devices presented innovative fiber laser technology that allows for decreasing treatment time and increasing procedural efficiency. The super pulsed laser system is based on the thulium fiber laser technology developed for stone lithotripsy and soft tissue applications.

Regulatory approval and initial testing

The presented laser system obtained the regulatory approval that enables the application of the fiber laser in the medical world globally. The fiber laser system has already been tested on synthetic kidney stones and demonstrated that this technology can dust stones in half the time it takes other systems, while also creating a fine dust that is easily removed.

Clinical advantages of the super pulsed fiber laser

The laser beam application in early cases leads to the system having practically no retropulsion at chosen settings, and the fiber laser provides accurate soft tissue cutting with visibly improved hemostasis capability. The super pulsed thulium fiber laser system changes the game rules in medicine.

Faster stone fragmentation and patient benefits

The laser system is considered to be faster; it dusts stones into tiny particles that more easily wash out during the procedure, which is a crucial advantage for patients. “When kidney stone fragments don’t clear during or after the lithotripsy procedure, they can potentially grow into bigger stones that lead to future stone-related events such as painful colic and the need for urgent intervention.”

Superior performance and a unique laser module

This fiber laser technology is regarded as highly promising and even superior in several features and performance metrics. The operating principle of the fiber laser is based on a laser module configuration unique within the medical area, providing the broadest range of settings available, containing very low energies and high laser beam frequencies that can transmit superior performance across a range of applications.

Optimized wavelength and energy absorption

The laser beam has energy emitted at 1940 nanometers (the optimal wavelength for peak absorption in water), and it is possible to increase energy absorption four times greater than conventional fiber laser systems used as the current standard of care market today. Also, the super pulsed fiber laser provides ergonomic and environmental benefits.

Compact and efficient design

This laser system is very compact compared to similar systems; for example, it fits on a standard wheeled OR cart, as well the fiber laser demonstrates higher efficiency, while it needs just a standard 110-volt power outlet. The fiber laser system is significantly quieter than other systems, producing 50% less noise at comparable settings.

Selective sintering with fiber laser technology

The selective sintering based on fiber laser technology is considered to be a process that applies a laser system to heat powder materials, leading to the fusion of micron-scale particles to create a solid mass. This technique finds its popularity in numerous manufacturing processes today. Previously, laser technology has been limited to printing with one material at a time.

Overcoming the limitations of single-material printing

The problem has been overcome by changing the whole laser system process to provide printing with multiple materials. Scientists moved the fiber laser so that it points upward instead of downward into the heated place, leading to no need for a powder bed.

Use of glass plates and powder coating

The scientists installed several transparent glass plates, and they coated them with a thin layer of various plastic powders. They make a print platform lower onto the upper surface of one powder, therefore, directing a laser beam of high quality upward from below the plate and through the bottom.

Advantages of multi-material sintering

This fiber laser technology enables numerous materials to either be combined into a single layer or stacked. Thus, a large powder bed is not required anymore because it promotes the sintering of various powders in a single layer. Also, a prototype laser system has already been tested and shows “a 50-layer-thick, 2.18-mm sample out of thermoplastic polyurethane (TPU) powder with an average layer height of 43.6 μm, and a multi-material nylon and TPU print with an average layer height of 71 μm.”

Stronger and denser materials with fiber lasers

The fiber laser system for 3D printing offers such qualities as the feasibility of the process and the capability to make stronger, denser materials by pressing the plate hard against the hanging part during the process of sintering by the fiber laser.

Future applications of fiber laser 3D printing

Finally, the scientists claim that laser technology is regarded as highly promising and can find potential applications in printing embedded circuits, electromechanical components, and even robot components. Laser beams enable to production of machine parts with graded alloys, whose composition transforms gradually from one end to another.

Expanding opportunities for additive manufacturing

The opportunities of laser systems for sintering will be greatly expanded toward a wider variety of industries by allowing the production of complex multi-material parts without assembly. The fiber laser technology can change the additive manufacturing industry from printing only passive uniform parts, toward printing active integrated systems.

Fiber lasers and geothermal drilling efficiency

The high-powered fiber laser system demonstrates high efficiency during field testing to make hard rock weaker, improve the cost of geothermal drilling, and a laser beam process applied to achieve geothermal heat that is considered to be a clean and stable source of energy.

Problems of traditional drilling

The drilling process deep into the earth’s crust leads to an increase in the drill bit temperature; in this case, the drill bit wears faster and its penetration rate reduces. The cost of drilling without fiber laser application is extremely high, and this problem deters investors from being involved with deep geothermal projects.

New fiber laser technology for hard rock drilling

Nevertheless, a team of researchers from Germany has developed a fiber laser technology for laser beam drilling of hard rock that potentially allows both enhancing the penetration rate of geothermal drilling and saving the cutting edge of the bit by loosening and destroying the rock immediately before the drilling begins.

Operating principle of the developed system

The operating principle of the system developed is based on the installation of a ytterbium fiber laser (with an output power of up to 30 kilowatts) on a test rig. The fiber laser system has already been tested on such materials as sandstone, granite, and quartzite, all of which are regarded as hard rocks with a strength of more than 150 megapascals.

Role of water-jet and laser optics protection

The researchers apply a water-jet to direct the laser beam to the rock face, like an optical fiber directs the laser beam. This fiber laser technology protects from contamination and damage to the sensitive laser optics and simplifies the removal of the rock debris by the drilling device. Then the team employs “the laser system on the drilling rig in a specially developed drill string and tests the new tool under realistic conditions in field trials, which also proved to be a success.”

Future improvements of fiber laser drilling

Additionally, the researchers plan to further increase the distribution of the laser beam power and add several sensors to the hybrid device to receive feedback from the drilling process by the fiber laser system, resulting in the opportunity to respond to changes in material along the drilling path.

Adjustable laser power for drilling processes

It is possible to quickly adjust the output power of the fiber laser, making it particularly helpful in drilling processes. This type of drilling system, based on fiber laser technology, allows decreasing the cost of deep geothermal drilling in the future and expanding the application of geothermal energy as an inexhaustible source of energy, replacing other renewable sources, for example, sunlight, wind, and water.

Challenges of precise metal cutting

The process of precise metal cutting by hand is considered to be challenging, which is why there is a demand for safer, quicker, and easier technology. Fiber laser technology is perfect for cutting because it focuses on laser beams of light to cut different materials, especially metals that are difficult to process compared to standard ones, such as wood, acrylic, and MDF.

Comparison of CO2 and fiber laser cutters

Numerous types of laser system cutters are distinguished; however, CO2 and fiber laser cutters are regarded as the most popular. These systems are very different from one another; they can be dangerous if applied improperly.

Safety issues with CO2 laser systems

CO2 laser systems use oxygen assistance to cut metal. Safety rules are highly important here because these laser systems can provoke lacerations, burns, and immediate blindness, as well as combustion or explosion (because of oxygen) when employed improperly.

Safety issues with fiber laser systems

Fiber lasers, in turn, have a higher level of power; therefore, they also have similar consequences when used improperly. Is it very important to wear safety equipment? For example, safety glasses and gloves are required when working with fiber lasers, and the appropriate laser beam coatings.
Additionally, the application of fiber laser systems requires a well-ventilated room because some laser systems can emit noxious or even toxic fumes.

Cost and application considerations

There is an opinion that laser beam cutting is a challenging task since some metals are difficult to cut because of their properties (density, reflectivity, and the way they absorb heat).
Sometimes the cost of CO2 laser systems is cheaper, but they always need oxygen and are limited to cutting less-reflective metals, while fiber lasers do not require any additional components, but their cost is typically higher. Thus, the cost of both types limits the metal cutting to professional and industrial applications.

Expert advice for better cutting results

Experts offer several pieces of advice to make the laser beam cutting process easier and faster, and get the best results. It is necessary to pay careful attention to various materials processed by CO2 or fiber laser systems.

Practical recommendations

The advice is the following:

• Elevate the material by a platform raised on spikes in order to decrease the heat dissipation.
• Conduct tests in order to save a lot of future hassle.
• Separate the gas from the laser system if oxygen or nitrogen is used for safety. 
• Make good cuts.

Introduction to fiber laser weapons

Technological advancement achieved a significant milestone when weaponized laser systems mounted on vehicles became a reality. Vehicle-mounted laser beam weapons are considered to be a low-cost device for improving combat capabilities, applied by both regular and irregular armies involved in almost every conflict in the world.

Evolution from conventional weapons

Until recently, options for mounting weapons on combat vehicles have been limited to machine guns and artillery systems of various types. The situation began to change with the emergence of fiber laser systems or directed laser beam energy systems that produce enough power to burn small aircraft and ammunition in the air.

Advances in fiber laser technology

The placement of large power storage units on such systems has always been a serious problem, but recent developments in fiber laser technology have reduced the size of lasers to allow them to be installed even on a large jeep.

Historical background and technological development

In the 90s, there was a technological revolution in fiber optic communications, which accelerated the development of high-power solid-state laser systems, which found application in industrial processing a decade later – branding, cutting, welding, and melting.

Scaling fiber lasers for long-range applications

These laser systems are extremely effective at short distances, but it was a matter of time for the industry to find a way to scale this fiber laser technology and develop futuristic weapons that could cut and melt targets at a distance of several hundred or even thousands of meters.

Military interest and unique properties

Interest in military applications of fiber lasers increased immediately after the demonstrations of the first quantum generators. The unique properties of laser beam radiation, directivity, monochromaticity, coherence, generation of ultrashort pulses, and high energy concentrations are regarded as very attractive for various weapons systems. 

Functional roles of fiber lasers in military systems

Laser systems include devices employed to perform measurements and even functional sensors. For military applications, this type of fiber laser system is applied for guidance or target designation, rangefinding (determining the distance to the target), control of combat vehicles (proximity sensors), detection, tracking, and visualization of targets (laser beam radars), and countering enemy electronic-optical tools.

Controversies and the history of laser weapons

Fiber laser weapons always cause a lot of controversy. Some people consider it a weapon of the future, while others categorically deny the likelihood of effective examples of such weapons appearing shortly. People thought about laser beam weapons even before they appeared.

Types and characteristics of lasers

Since the development of the first laser system, a huge number of ways to obtain laser beam radiation have been found. There are solid-state lasers, gas lasers, dye lasers, free-electron lasers, fiber lasers, semiconductor lasers, and other laser systems.

Excitation methods and wavelength variations

Lasers differ in the method of excitation. For example, in gas laser systems of various designs, the active medium can be excited by optical radiation, electric current discharge, chemical reaction, nuclear pumping, or thermal pumping. The emergence of semiconductor lasers leads to DPSS (diode-pumped solid-state) laser systems.
Various designs allow obtaining different wavelengths of laser beam radiation at the output, from soft X-ray radiation to infrared radiation. Laser systems that emit hard X-rays and gamma-ray lasers are still in development. It enables choosing the fiber laser according to the issue at hand

Selecting fiber lasers for military use

As for military applications, this means, for example, the possibility of choosing a fiber laser system with wavelength radiation that is minimally absorbed by the planet’s atmosphere. Since the development of the prototype, the power has continuously increased, the mass and size characteristics, and the efficiency of lasers have improved.

Key components of fiber laser weapons

It is clearly visible in the example of laser modules. Of course, fiber laser modules are not suitable for creating combat lasers, but they are, in turn, used for pumping efficient solid-state and fiber laser systems.

Laser beam focusing systems

An important element of the system is the high-quality laser beam focusing system – the smaller the spot area is on the target, the higher the specific power is that allows damage to be caused. Progress in the development of complex optical systems and the emergence of new high-temperature optical materials allow for the production of highly efficient focusing systems.

Beam aiming and tracking

Another important component that makes it possible to create a laser beam weapon is the development of systems for aiming and holding the beam on the target. Gigawatt power is required to hit targets with an “instant” shot, in a fraction of a second, but the creation of such fiber laser systems and power sources for them on a mobile chassis is a matter of the distant future.

Guidance and atmospheric compensation

Accordingly, it is necessary to hold the spot of laser beam radiation on the target for some time (from a few seconds to several tens of seconds) to destroy targets with lasers of hundreds of kilowatts – tens of megawatts. This requires high-precision and high-speed drives that can track the high-quality laser beam on the target, according to the guidance system.
The guidance system must compensate for the distortion introduced by the atmosphere, when shooting at long distances, for which the guidance system can use several laser systems for various purposes, providing accurate guidance of the main “combat” laser beam on the target.

Fiber lasers vs other high-power lasers

Because of the lack of power sources for optical pumping, gas-dynamic and chemical laser systems have received priority development in the field of weapons. Despite all the benefits provided by gas-dynamic and chemical lasers, they have significant disadvantages: the need for consumable components, launch inertia (according to some data, it is up to one minute), significant heat generation, large dimensions, and the output of spent components of the active medium. These lasers can only be placed on large areas.

Advantages of solid-state and fiber lasers

At the moment, the greatest prospects are for solid-state and fiber laser systems, which only need to provide them with sufficient power to operate. The US Navy is actively working on free-electron fiber laser technology. An important advantage of fiber lasers is their scalability, i.e., the ability to combine several fiber laser modules to get more power.

Vehicle integration and modularity

Modern laser systems adapt to any vehicle that you want to use at the moment, and that’s why this technology is so impressive; it provides the flexibility of the architecture to fit different vehicles without much refinement. It allows the development of a system to support both a combat team and a forward operating base.
The system applies commercial fiber lasers assembled into easily reproducible modules, which makes it very affordable. Using multiple fiber laser modules also reduces the likelihood of minor faults, as well as the cost and volume of maintenance and repair.

Tactical benefits of fiber laser weapons

There are several characteristics of a directed energy tactical weapon that make it very attractive to modern armed forces, including the low cost of “ammunition” and its speed, accuracy, and ease of use.

Precision and speed

First of all, it is an accurate weapon with potentially low indirect damage. The speed of laser beam light allows instant irradiation of the target, and, therefore, it is possible to hit highly maneuverable targets, i.e., keeping the laser beam on the target, which sometimes can not cope with kinetic ammunition.

Cost efficiency

Perhaps the most important benefit of such fiber laser systems is the low cost of one effective “shot”. For instance, at this point, you don’t want to spend expensive and powerful defensive kinetic weapons on cheap multiple threats. Laser beam weapons are regarded as an addition to kinetic systems.

Applications against drones and missiles

The laser system is used against a large number of cheap threats of low intensity, leaving your kinetic force for attacking complex, armored, long-range threats. This type of fiber laser can be employed to protect against flying drones. For example, an American company introduced a laser system to protect objects from drones. 
A combat laser system shot down five aircraft-type drones during tests in 2017 in New Mexico. The fiber laser system is called ATHENA (Advanced Test High Energy Asset, a high-energy system for advanced testing). The operating principle is based on a 30-kilowatt fiber laser.
Another application of the laser system was demonstrated using a fiber laser system against missiles.  A message published on the company’s website informs that the engineers have managed to solve the issue related to the heating of the high-quality laser beam installation, as well as its compactness, thus creating an ideal protection system. 
The engineers claim that this is the only company that has an integrated fiber laser weapon system at an acceptable level of power and accuracy, which they have achieved with the ADAM (Area Defense Anti-Munitions) and ATHENA (Advanced Test High Energy Asset) laser systems.