Category: Applications of Fiber Lasers

Challenges of traditional surgical tools

A team of engineers from the U.S. has created a microrobot that allows for directing a laser system within the body to perform minimally invasive surgery. Traditional energy-delivering tools are very complex compared to the new fiber laser. It is necessary to put them close to the target site, resulting in limitations of accuracy.

Risks of conventional laser systems

Additionally, such laser systems can lead to unwanted burns in adjacent tissues and a smoky appearance. Even though fiber laser systems are regarded as very promising solutions, they are required to meet additional requirements. The direct application of current fiber lasers for minimally invasive surgery is limited by the following factors:

• the size of surgical systems;
• levels of accuracy;
• repositioning, steering, and manipulation.

Integration of fiber lasers with microrobots

The novel fiber laser system combined with the microrobotic end-effector can be widely applied in traditional endoscopic systems for application in minimally invasive surgery. The microrobot has a size of 6×16 mm, and it provides high speed and accuracy, and can operate with current endoscopic devices.

Benefits of the new system

The team members claim that their fiber laser technology promotes accurate direction of laser beams at small target sites in complex patterns to advance minimally invasive surgery by laser systems inside the body. Such benefits as “a large range of articulation, minimal footprint, and fast and precise action” make novel fiber laser systems very promising to increase surgical capabilities in a plug-and-play fashion.

Operating principle and design

A surgical fiber laser has to be both the diameter of a drinking straw and relatively nimble. The operating principle of the microrobotic laser system is based on the three compact mirrors that rapidly rotate to direct and redirect the laser beam in a compact surgical system.

Microfabrication and efficiency

The microfabrication technique is used to make the system smaller. This fiber laser technology offers a highly efficient fabrication process. The fiber laser has already been tested and demonstrated the high efficiency of microrobots in creating and following complex directions.

Surgical performance and outcomes

Numerous laser beam ablations can be carried out at a fast speed over a large range and with a high level of precision. The team showed efficient performance of the fiber laser system by integrating it at the end of an endoscope. This non-disruptive solution enables the team to increase the opportunities of minimally invasive surgeries in the human body with life-altering or potentially life-saving impact.

Application of fiber lasers in geothermal drilling

A high-power fiber laser has been successfully tested in field trials to weaken hard rocks to increase efficiency and reduce the cost of geothermal drilling. The fiber laser technology promotes a process applied to access geothermal heat, a clean and sustainable energy source.

Challenges in deep-earth drilling

When drilling deep into the earth’s crust, the drill bit’s temperature rises by approximately three degrees Celsius for every 100 meters, and upon striking hard rock, the drill bit experiences more rapid wear, leading to a reduction in its penetration speed.

Costs and research motivation

The cost of this process is high and often prevents investors from continuing with deep geothermal projects. Therefore, a group of researchers from Germany developed a method for mechanical drilling of hard rocks employing a laser system.

Design and operation of the fiber laser system

This fiber laser system can not only increase the penetration rate in geothermal drilling but also help to maintain the cutting edge of the drill bit by loosening and even breaking the rock just before drilling begins.

Technical specifications

The researchers have developed this laser system by initially installing a test unit with a ytterbium-based fiber laser with an output power of up to 30 kilowatts, which they then used to successfully loosen sandstone, granite, and quartzite. All these materials are solid rocks with a strength of more than 150 megapascals, up to 80 percent.

Laser guidance and safety

A jet of water is used to direct the laser beam to the rock surface – similar to how an optical fiber can direct a laser system— which also prevents contamination and damage to sensitive fiber laser optics and makes it easier to remove rock fragments with a drilling tool.

Field testing and future improvements

Then the engineers use a fiber laser system on the rig in a specially designed drill string and test the new tool in real-world conditions in field tests, which also proved successful. In future projects, the researchers plan to further improve the laser beam power distribution and add digital sensors to the hybrid tool to get feedback from the drilling process and thus be able to respond to material changes on the drilling path.

Advantages and potential impact

The flexible adjustment of the laser beam output power is one of the factors that make it a particularly effective tool for facilitating drilling processes. According to the researchers, the developed powerful fiber laser system will help reduce the cost of deep geothermal drilling in the future and simplify the use of geothermal energy as an inexhaustible source of energy-supporting other renewable sources such as sunlight, wind, and water.

Modern applications of laser technology in defense

The fantastic application of laser systems has become true, and today, weapons based on laser technology are used, whether in the hands of infantry, mounted on trucks, armored vehicles, warships, or even Air Force fighters. It is planned to use fiber laser systems for the destruction of cruise missiles.

How fiber lasers destroy targets

Fiber lasers emit a laser beam to create intense heat. It means that these laser systems offer practically inexhaustible “ammunition”; the cost per shot is pretty low compared to a missile or even a cannon shell. Other advantages of fiber laser systems include fast speed and accuracy, although they are considered to lose coherence over distance.

“The more powerful the fiber laser, the further it can go and the quicker it burns through its target – but the larger its power supply and cooling system have to be.” The U.S. Army confirms that ground-based laser systems will ensure an effective and cost-efficient laser device that allows defense against drones and surface-skimming cruise missiles.

Efficiency against UAVs and drones

Fiber laser systems demonstrate their particular efficiency as short-range air defense systems against Unmanned Aerial Vehicles because of their common slowness. Thus, the laser system has enough time to burn through the drone’s skin and damage critical bits of the airframe. Moreover, anti-drone application of laser technology has already been tested and was recently employed in combat for the first time when a Turkish laser system applied by a faction in Syria stopped an enemy drone.

It is planned to create the first four-vehicle platoon of eight-wheel armored vehicles equipped with a turret-mounted 50-kilowatt fiber laser system. These laser modules will become a common support asset in U.S. brigade combat teams.

Challenges with cruise missile defense

Laser systems face great challenges from jet-powered cruise missiles. The thing is that even slow missiles tend to scream towards their targets at 500–600 miles per hour, resulting in little time left for fiber lasers to stop the missile’s skin target.

Technical considerations for missile interception

Additionally, the fiber laser system has to somehow cause heat damage to an element that will avert the cruise missile from sailing forward on sheer momentum to hit its target because the laser module does not use kinetic force to “push” the missile. Now the development of the 100 KW laser system is regarded as an interim step before the creation of a 250 or 300 KW weapon based on the laser technology, resulting in overcoming “more stressing threats”.

New generation of laser modules

A new generation of laser modules has been developed for secure identity, payments, and data protection. These modules allow customers to implement advanced laser technology in both financial payment cards and government ID cards. Fiber laser technology is rapidly gaining popularity across financial and government card markets. This growth is driven by rising demands for stronger security and greater personalization. The design team combined years of experience with modern advancements in fiber laser technology, achieving more precise image quality and detailed engraving.

Role in security and image quality

Fiber laser technology plays a key role in meeting strict security and image quality requirements, as counterfeiters become increasingly sophisticated. Its precision makes fiber lasers an essential part of any security strategy, ensuring accuracy and durability in engraving.

Government applications

Modern fiber laser systems are widely used in government applications. They deliver sharp edges and clear images, support high-quality photos, text, barcodes, and various additional security features. These modules meet the security standards of most government agencies worldwide.

Flat and metal cards have led the financial card market to adopt new fiber laser technologies for durable graphics and engraving. The latest modules enhance personalization with modern fiber laser engraving systems. They feature a user-friendly interface that allows full customization and can engrave barcodes, text, and bitmap images on various materials.

Additional security features and technology

Fiber laser modules can also include advanced security features. They offer easy setup and control, multimodal laser integration, and built-in vision registration cameras. The camera aligns engraved and pre-printed elements precisely. Some modules include air-cooled fiber lasers — compact units that require no external cooling while maintaining strong performance.

Modern fiber laser designs have significantly improved in efficiency and versatility. These systems deliver reliable, energy-efficient performance, making them suitable for a wide range of applications and environments, even with limited budgets.

Growth of the battery manufacturing market

According to researchers, battery manufacturing has become a rapidly growing market, mainly driven by increased demand from the electric vehicle (EV) industry. Fiber laser manufacturers anticipate strong growth in integrating fiber laser technology into battery welding equipment, especially laser-based systems.

Fiber laser principles are applied in battery welding. While this is not a new application, its use surged with the growth of the EV industry.

Research and development in battery cell production

Researchers are currently developing efficient production centers for EV battery cells. They investigate how fiber laser technology can economically join dissimilar materials, improving the efficiency and reliability of battery manufacturing.

Projects on lithium-ion battery manufacturing

Several scientific projects explore fiber laser applications in battery production. One study focuses on optimizing lithium-ion battery manufacturing. Researchers designed a fiber laser system to join anodes (copper) and cathodes (aluminum) to contacts. Various fiber laser types were tested, and a turntable with multiple stations enabled a complete stack in just two seconds.

Efficient battery cell connections

Another project examines more efficient connections of battery cells. Scientists are developing processes for bonding copper, aluminum, and steel using nanosecond fiber lasers. These processes are challenging because thin electrical contacts are sensitive to heat. Low welding energy results in weak mechanical stability, while excessive energy can reduce battery lifespan. Striking the right balance is critical.

Experiments on different joint types

A third project tested copper-aluminum and copper-steel joints on pouch and cylindrical cells. The results showed joint quality comparable to continuous-wave (CW) welding, with lower energy consumption, high repeatability, and fewer intermetallic phases. The main drawback is longer processing time, highlighting areas for further improvement.

Fiber laser systems have broad applications, including battery manufacturing. They can combine CW and nanosecond pulsed fiber lasers, with separate control of the laser beam. Beyond joining, fiber lasers can also remove material to shape surfaces or create precise structures.

Fiber lasers beyond science and industry

We all recognize the impact of fiber laser technology across various scientific fields. The precision of fiber laser beams has become essential in medicine, telecommunications, and more. Yet, few people are aware of their applications as artistic tools — and this isn’t about restoring old artworks through cleaning techniques.

Fiber lasers can cut intricate patterns in materials such as paper, wood, and metal. These patterns are highly resistant to harsh environments and chemical exposure. Researchers have leveraged these properties to develop a fiber laser system useful for artists and designers.

A research team in Russia recently created a fiber laser paintbrush. This tool enables designers to add, modify, or erase strokes on a titanium canvas with remarkable precision.

Creating colors with fiber lasers

Oxidation-based full-color palette

The device uses fiber laser-induced oxidation to produce a full spectrum of colors on stainless steel — no external pigments are required. The laser forms an oxide layer on the metal surface, with a specific thickness and chemical composition for each color. By carefully adjusting the laser parameters, researchers were able to control color development.

Erasing and rewriting colors

To modify or remove colors, the team designed a printer incorporating a nanosecond ytterbium fiber laser with a scanner to move the beam. Heating the titanium surface with the laser creates an oxide layer, generating colors. A second pass reduces brightness, and slight adjustments to intensity and scanning speed can fully erase the color.

The researchers demonstrated the system by creating several renowned art pieces. What would take traditional artists years to complete could be produced in just three minutes using the fiber laser system.

The team is working on a handheld version of the fiber laser system, allowing artists to use it more like a conventional pen or brush, increasing accessibility and creative freedom.

New fiber laser technology in lithotripsy

Dusting kidney stones with super-pulsed fiber lasers

A health organization in the USA tested a newly developed fiber laser capable of turning kidney stones into dust-like particles. This technology allows specialists to reduce even large kidney stones to tiny particles, which can then be suctioned or flushed from the patient’s body. The super-pulsed fiber laser targets the water within the stones, transforming a stone the size of a thumb into particles of 100 microns or less.

Rising need for effective kidney stone treatments

Statistics show that the number of Americans with kidney stones has doubled in recent years. More than 10% of the population has experienced a kidney stone at some point. This growing prevalence has driven scientists to seek more effective treatment techniques, including fiber laser systems.

Advantages of fiber lasers over traditional lasers

Thulium fiber laser vs. holmium laser

As fiber laser technology has advanced, it has been applied in lithotripsy to break up stones without the need for incisions. A specialist can use a fiber laser to precisely locate and fragment stones. Compared to traditional lasers, the thulium fiber laser can split kidney stones into particles 10 times smaller than those produced by a standard holmium laser. Smaller particles are easier to remove.

Improved clearance and patient outcomes

Research shows that a holmium laser clears about 50%–60% of stone fragments, while a thulium fiber laser can clear over 90%. Clinically, this technology has the potential to make procedures less painful and costly than surgical removal. With the fiber laser system, there are no incisions and minimal risk of complications such as bleeding or infection. Patients also do not require an overnight hospital stay.

Future developments and surgical innovations

Researchers are now developing a sensing device to prevent ureter injury during stone surgery. This device will be used with the thulium fiber laser. Combined, these technologies have demonstrated 94% clearance rates. Both innovations contribute to the evolution of surgery and improved quality of life for patients.

U.S. Army testing and deployment plans

The U.S. Army is conducting final tests of a high-energy fiber laser weapon. This system can be used against rockets, drones, and other aerial threats. These fiber lasers are installed on military vehicles and have already participated in various combat simulations. The first platoon equipped with these systems was expected to be deployed in 2022.

History and development of fiber lasers

Initially, fiber lasers were viewed as part of science fiction. They were first invented in the 1960s. Over the years, scientists developed higher-power fiber laser systems while making them smaller. This made it possible to use laser modules in tactical environments and reduce space requirements.

Expansion into military applications

With continuous improvements, fiber laser technology has become one of the most advanced modern fields, applicable in almost every area. The military is no exception. For example, the Navy is running a program to install a fiber laser weapon on a destroyer. This system provides new energy capabilities, optical dazzler technology, and long-range intelligence support. High-energy fiber laser systems are also being tested to disable enemy drones.

Tactical advantages of fiber laser weapons

Fiber laser weapons have become a reality and are expected to play a key role on future battlefields. Development accelerated in recent decades due to the growing threats of armed drones and rocket attacks. As reaction time to such threats is limited, it was important to create compact and powerful laser systems capable of responding within seconds.

Engineering challenges and solutions

It was a major challenge for engineers to design a laser module powerful enough to neutralize a mortar shell from a mile away. This became possible thanks to technology that combines multiple laser beams into a single high-power output.

Operational benefits

Fiber lasers provide strong defense against unmanned aircraft systems and artillery. They enhance the Army’s air and missile defense capabilities while reducing overall life cycle costs and logistical demands. The plan included deploying four battalions equipped with these systems by 2022. This is not the final step: the Army is developing a more powerful 300 kW laser module to be mounted on a truck, expected to enter service in 2024. This laser would be capable of disabling cruise missiles.