Ultrafast Lasers: Powering the Future of Innovative Manufacturing

ultrafast pulsed lasers

Unique Characteristics of Ultrafast Pulsed Lasers

The truly unique and promising characteristics of the ultrafast pulsed lasers have opened up new opportunities for processing special materials. It means the materials that use ultrashort pulse widths and extremely high peak intensities. Currently, ultrafast pulsed lasers are increasingly being utilized for both fundamental research and practical applications. The laser manufacturing market is currently expected to exceed $17 billion in value by 2020 and grow at a rate of about 6 percent for the next five years. This fast, steady increase is due to wide use in various parts of the science world, including aerospace, automotive, and biomedical.

Conventional fiber laser techniques that commonly use nanosecond and longer pulses are hopelessly outdated: they are being replaced by materials processing with ultrafast lasers. The aforementioned fiber lasers can be used for working with such materials that require special conditions where the thermal influence must be minimized, for example, during the drilling of metals and cutting wafers, polymeric stents, and display glass. The companies that manufacture lasers produce more and more ultrafast lasers (also known as ultra-short pulse): picosecond and femtosecond fiber lasers. These ultrafast laser systems have a temporal pulse (the amount of time the laser light is in contact with the material) that is three to six orders of magnitude shorter than conventional fiber lasers.

Picosecond and Femtosecond Fiber Lasers

  • Picosecond fiber lasers emit optical pulses between 1 ps and some tens of picoseconds.
  • A femtosecond fiber laser emits optical pulses with a duration well below 1 ps.

The quality comparison between picosecond and femtosecond lasers is material-dependent. It can be very subtle or very apparent in different instances. The femtosecond ultrashort pulsed laser is a clear choice when the absolute best quality is needed, but it should be noted, the picosecond ultrafast fiber lasers tend to machine faster.

Ultrafast Laser Processing Applications

Ultrafast laser processing has fundamentally changed the way of materials microprocessing with fiber lasers. Ultrafast fiber laser has become a micromachining tool for various materials, including metals, semiconductors, ceramics, glass, crystals, polymers, and even soft materials like biotissues. In addition to this, these scientific ultrafast laser systems have also been employed for several practical and industrial applications. These fiber lasers are now also used in the electronics industry for scribing, patterning, and texturing of glass and semiconductors.

Advantages in Precision and Heat-sensitive Material Processing

As devices become smaller and more complex, laser machining will have to continue to push the edges of performance. Now we already know that the ultrashort pulsed lasers can produce nanoscale holes. Fiber-optic laser systems can deliver a very precise concentration of light over such a short duration. This feature helps to avoid heat damage to the surrounding material and makes such ultrafast lasers irreplaceable for machining heat-sensitive biomaterials.

Contemporary developments in ultrafast laser industry

ultrafast lasers

Progress in ultrafast lasers over the last decade

The last decade has been marked by significant progress in the field of ultrafast lasers, which generate optical pulses in the picosecond and femtosecond range. Specialized laboratory laser systems, in other words, have been transformed into compact, reliable instruments. These laser systems have been dramatically improved and opened up new frontiers for applications by achievements by dint of developments of semiconductor lasers for optical pumping and fast optical saturable absorbers, based on either semiconductor devices or the optical nonlinear Kerr effect.

Market growth and applications

The ultrafast laser market is not just growing, it is accelerating. Ultrafast lasers are able to provide high peak power without thermal damage, which makes them better suited for biomedical and biological applications. The major factor driving the growth of the ultrafast laser market is the rise in demand for ultrafast lasers across biomedical applications. Also, another major factor is increasing the need for cost-efficient solutions for micromachining. The global market for ultrafast lasers is expected to reach nearly $5,5 billion in 2019, registering a compound annual growth rate of 23,7% for the period 2014-2019.

Principles of ultrafast pulsed lasers

The action of ultrafast pulsed lasers is based on such phenomena of ultrafast optics and ultrafast laser physics as like Kerr effect and saturable absorbers. The Kerr effect leads to self-phase modulation. It also allows for Kerr lens mode locking. Related nonlinearities, such as Raman scattering and self-steepening, occur when the nonlinearity has a finite response time. Saturable absorbers, in their turn, used for passive mode locking, introduce optical losses which are reduced for high optical intensities.

Types of ultrafast lasers

The most important types of ultrafast lasers are Ti:Sapphire lasers, diode-pumped lasers, fiber lasers based on rare-earth-doped glass fibers, and mode-locked diode lasers. Several important applications benefit from laser development.

Ultrashort pulse duration

Ultrashort pulse duration. The ultrashort pulse of light is an electromagnetic pulse whose time duration is of the order of a picosecond or less. These pulses have a broadband optical spectrum and can be created by mode-locked oscillators. This special pulse duration allows fast temporal resolution.

High pulse repetition rate

Lasers with multi-gigahertz repetition rates are key components of many applications. They are used in high-capacity telecommunication systems, photonic switching devices, optical interconnections, and the like. High average power 10-2100 GHz sources at shorter wavelengths are promising sources for optical clocks in integrated circuits. Optical clocks can be precisely injected into specific circuits inside a VLSI microprocessor and have the potential to reduce on-chip power requirements, skew, jitter, and scaling to high clock rates beyond 40 GHz.

Broad spectrum

The broad spectrum supports good spatial resolution for optical coherence tomography, a technique for non-invasive cross-sectional imaging in biological systems. Also, the broad spectrum can be useful for stabilizing the electric field underneath the pulse envelope, which is important in highly nonlinear processes such as photoionization and high-harmonic generation.

High peak intensity

The high peak intensity of the pulse can be used to alter materials by “cold” ablation (when a material is changed to gas directly from a solid) or to generate other colours/wavelengths through nonlinear frequency conversion.

Ultrafast lasers have been developing for three decades and are expected to develop further in the future. The main features that are expected to improve are pulse frequency, power levels, and manufacturing costs.

Modern fiber lasers enable new materials processing applications

modern fiber lasers

Key features of modern fiber lasers

Modern fiber lasers differ from other industrial laser sources by their brightness, stability, and flexibility. Fiber laser systems are widely used in the manufacturing industry because of their efficiency, reliability, quality, and low cost of operation, which makes it possible for machines to cut, weld, mark, and micromachine materials.

All the industrial fiber lasers are distinguished by their unique properties that include a sealed optical cavity and a single-mode, guided-wave medium. Modern fiber laser systems have an absolutely sealed optical path that is non-sensitive to environmental contamination; it remains optically aligned and doesn’t require adjustment. Fiber laser systems have either in-fiber or hermetically fiber-coupled internal components.

Pulsed and Continuous Wave (CW) green fiber lasers

All the higher-power fiber lasers combine several single-mode modules into a high-brightness delivery fiber in fused fiber combiners. This union of the waveguiding of a single-mode laser and the fully sealed optical cavity guarantees a reliable laser design that is fixed and measured during the manufacturing and has minimal change over time and temperature. Sealed pump diodes and unbreakable fiber technology allow creating fiber laser systems that can be used in production for several years without any adjustments or degradation.

Fiber lasers vs. disk lasers

The choice between fiber laser and disk laser sources depends on commercial considerations of service and support, and, of course, added-value features. The main problem of fusing glass is resolved by fiber laser manufacturers, and it can withstand the intensity that melts or ablates different metals, while disk laser manufacturers create the precision optical-mechanical-thermal design with the aim of making a stable, high-brightness output.

Main fields of application

The fields of fiber laser application:

  • High-speed remote welding. At the present time, laser welding is more preferable than ultrasonic and resistance welding because of the productivity and weld strength qualities.
  • Materials processing. The brightness, stability, and flexibility of fiber laser system designs enable new materials processing uses, even including on-the-fly settings or adaptation of the process to changes in materials in production.
  • Manufacturing solutions. Fiber lasers become an ideal solution for manufacturing because they have high beam quality and do not require any adjustment or maintenance.

Laser systems provide fast data transmission from space to the Earth

laser communication for CubeSats

The role of lasers in modern life

Lasers and laser systems have become an essential part of modern life. The fields of their application are not limited to physics and medicine. Laser modules are quite often used at space stations and demonstrate good results that will be useful for space exploration. A team of researchers is developing a novel technology that will provide high-bandwidth communication between CubeSats and the Earth with the help of laser systems. This laser module technology enables the CubeSat to send a large amount of information with a second directional laser beam to keep the primary data beam on focus without using any huge antennae or fuel wasting.

Why CubeSats matter

The CubeSat is considered to be a force for scientific, commercial, military, and space progress due to its low cost and compact size, which is about a loaf of bread. CubeSats allow the collection of data about the weather or anti-missile defenses, and they can be sent up at the right moment instead of a single, huge satellite.

Challenges in CubeSat data transmission

CubeSats are not so good at data transmission because they are able to send the information that is equal to several images at a time. New laser systems allow transmitting a large amount of hyperspectral images quickly, which is equivalent to a terabyte of data transmission at a high rate.

Limitations of traditional radio systems

Even traditional radio systems are not efficient with this type of information, and CubeSats’ access is limited; that is why space engineers now consider the use of laser modules to be a faster means of communication. The advantages of such laser systems include better bandwidth, compact size, and high power efficiency.

Technical difficulties with CubeSats

The small size of CubeSats causes a lot of problems for lasers. The main problem is the need for a tilt of the entire satellite to aim the beam, which is unacceptable because this costs time, energy, and fuel that the probe cannot afford to waste.

The new laser-pointing technology

The new technology allows pointing the laser module more precisely and keeps it on target without needing to move the CubeSat or to use a high-powered laser system. This laser-pointing platform exploits a compact laser that is reflected in a small, standard, steerable MEMS mirror to direct it at the ground receiver.

Main advantages of the system

The main advantage of the laser system is that not only does it point the laser, but it also helps to keep it locked on the target. The system has to recalibrate the mirror in orbit using two different color lasers (the data and the calibration beams). The technology allows producing a low-power system with the narrow laser beams on this small platform that is 10 to 100 times smaller than it was before.

Fiber laser systems: Space application

laser-powered interstellar travel

Interstellar travel and miniaturized spacecraft

Traveling through space is a lofty aspiration for humanity; creating something small might be essential to realize it. According to a new study, the use of powerful laser systems to launch tiny spacecraft will significantly speed up interstellar flights, and therefore, it will take only one or two decades instead of thousands of years. Physics and mathematics limit all the impulses. Also, the spacecraft should move incredibly fast to get there in a reasonable amount of time – but this requires a lot of fuel. And the necessary fuel loads will make the spacecraft too heavy.

Some researchers have found a way out of the current situation – it is necessary to use a solar, laser system, or microwave sail. This spacecraft will not require any fuel, but in order to provide the necessary acceleration to the big vehicle, people will have to develop a huge orbital laser module, and equip the spacecraft itself with a sail of Texas size.

Tiny sailing spacecraft and probes

It is possible to solve the problem with the help of a tiny sailing spacecraft. Space laser system probes that have just one gram in weight will be put into Earth orbit, and then accelerated by a laser beam of high quality. Each probe will be equipped with tiny optical sensors and transmitters to communicate with the Earth. In addition, the system can be developed and improved gradually, since even the use of heavier probes or a less powerful laser beam will allow exploring several distant parts of the solar system.

Required laser power and acceleration

The system requires the use of a laser module with a power of 50 to 70 gigawatts because it will enable accelerating the probe with a meter sail to 26% of the speed of light in just ten minutes. This space probe will reach Mars orbit in 10 minutes, it will pass the Voyager-1 in three days, and arrive in the Alpha Centauri star system in fifteen years.

In order for the idea realization, scientists will have to find a way to focus and very accurately direct the laser beam, as well as develop a tiny and light transmitter so that the space probes can transmit the received data to the Earth.

Fiber laser system operation principle

It will take almost 10 years to wait for the first probe launch, but now the development is going according to plan and promises the realization of the most ambitious projects. The principle of the laser system operation is the following: the fiber laser will send a signal from Earth into its orbit. The laser beam is captured and converted into kinetic energy, which is used for movement. It sounds like science fiction, but it’s actually pretty simple.

Installation of laser system modules

The laser system modules will be installed at high mountains, and the power of the emitters will be about 100 gigawatts. At the same time, special devices will be launched into orbit that will “catch” the laser beam. Each of them was created specifically for this system and is very different from the conventional space sensor:

  • its diameter is 13 ft;
  • the device weight is not more than 0.001 pounds;
  • the thickness of the device is only 400 atoms.

Advantages of ultralight spacecraft

The devices are a light haze, so that they can accelerate to 200 million km per hour with the help of a laser system. The space probe’s first mission is the study of Proxima Centauri, and even these ultralight laser module vehicles will be able to reach the destination point only after 25 years.
Lightweight is needed not only for quick acceleration, but in theory, it will help avoid collisions with asteroids. In this case, a small spacecraft has all the necessary equipment to obtain detailed information about the surrounding space. The very idea of mini-satellites has already been realized, and in 2017, Indian engineers tested mechanisms of 0,009 pounds, which successfully transmitted data to Earth for the first time.

Potential use of black holes for propulsion

It is believed that future spacecraft will be able to use black holes as powerful launching platforms for studying stars, which is one more laser application. A new study involves the emission of laser beams from a spacecraft along the edge of a black hole, which will bend around the latter because of its powerful gravity and return with added energy. The spacecraft will “catch” these laser beams, obtaining free energy, which can be used for its acceleration up to the speed of light.

Laser modules for space data transmission

Laser modules can be actively used for data transmission in space. A group of physicists from Switzerland has developed a fiber laser that generates a super-hot laser beam that allows making holes in the clouds. Another laser beam containing the whole information can be directed into such holes.

Overcoming atmospheric obstacles

The laser developed in Geneva allows transmitting 10000 times more information than radio waves. Until today, the problem was in the clouds and fog that occasionally appeared in the atmosphere, stopping the laser beams and distorting data.
Physicists have developed a laser system that heats the air in the right place to a temperature above 1500 degrees Celsius. As a result, a hole with a diameter of several centimeters is formed in the cloud.
A tunnel made by a laser beam can be maintained for some time while another beam transmits data. Scientists have tested their development on artificial clouds of 1.6 ft, but they contained 10000 times more water per square centimeter than natural clouds. The new method works even if the clouds are in motion.

Laser communication with exoplanets

It is quite possible that in the near future, these laser systems will allow communicating with possible aliens. Astrophysicists have calculated that hypothetical astronomers at Proxima Centauri b – an exoplanet that revolves around a star that is 4.2 light-years from Earth – would be able to pick up a signal sent using a two-megawatt laser module and an optical telescope with a 115-foot mirror.
The researchers calculated that if you used a powerful laser system and focused its beam using an optical telescope, the infrared radiation of the received signal could reach exoplanets, both rotating around our nearest Proxima Centauri and TRAPPIST-1 planets located at a distance of 40 light-years from Earth. According to scientists, such laser beams can be a kind of sign, the light from which extends to distances up to 20 thousand light-years.

Military and observational applications

For example, powerful laser systems developed for military aims already have needful power. Scientists specify that it will be necessary to install the fiber laser system at high points like powerful telescopes to reduce the noise of the Earth’s atmosphere, which can interfere with signal transmission. Much more powerful telescopes should be used to transmit such a signal.

NASA and ice layer observation

In addition to these potential fields of laser module application, they are used by NASA to study the ice layer of the Earth. Not so long ago, a NASA satellite was launched into Earth orbit from a California space center to study the state of the Earth’s ice cover.
The mission of an artificial satellite, called ICESat-2, is to provide more accurate information about the influence of global warming on the ice layer by a laser system.
As the name suggests, ICESat-2 is the second version of the satellite. The first spacecraft was launched in 2003, and it carried out a laser module test of the thickness of polar glaciers and sea ice from space for the first time. The mission faced technical problems, as a result of which observations were limited to only a couple of months in a year.
Since then, NASA has improved laser technology, making the observation process more reliable and focused. The laser beam is divided into six parts – three pairs, so we can see a larger surface of the ice, as well as evaluate the surface slope. The same ground surfaces will be measured every three months, giving us seasonal ice shots. It is possible to understand the processes associated with the reduction of ice in the polar regions due to the data.
The new laser system that weighs half a ton is one of the largest surface observation tools ever created by NASA. It uses photon counting technology. The probe emits 10 thousand laser pulses per second, and the laser module measures every 3 ft as it moves along the ice surface. The laser beam cannot melt the ice from a height of 3280 ft. At night, it is possible to see a green mark in the sky – this is the ICESat-2 satellite flying.

Laser systems for space debris removal

Laser systems are a possible solution for cleaning space from debris. An international team of scientists is developing a laser system to deal with space debris. Fiber lasers are expected to protect the space station from collisions with dangerous alien elements. According to analysts, physicists will have to overcome a number of technological difficulties. In particular, it will be necessary to find a balance between the power and energy intensity of the laser system.
Scientists are developing quite powerful laser modules that can change the orbits of small space debris – up to 0.3 ft in diameter. All the electric power generated by the ISS will be required to launch such a laser system, and it will completely leave the station without electricity.
Physicists confirm that space debris will dissolve under the influence of the laser module, forming a cloud of microscopic particles that pose no threat to the ISS covering or any other space equipment. At present, an impressive amount of garbage has accumulated in Earth’s orbit, but the situation is still far from critical.
The scientists propose to use special flying satellites and even special nets that will catch space debris. All these laser techniques are rather difficult to put into practice. The use of a laser technology that will dissolve parts of space debris seems to be the most realistic.

High precision of powerful fiber lasers for welding

high-power fiber laser systems

Importance of precision in high-power welding

High-power fiber laser systems that are necessary for welding of sheet metal, tubes, copper, and aluminum in heavy industries also require a high level of accuracy to avoid defects. That is why operators have a greater responsibility to provide this power with precision, and the development of laser system technologies remains important.

At the present time, there are numerous improvements in laser systems that allow solving the mentioned problem. For example, the high precision of a laser beam can be offered by laser power distribution to the inner and outer cores of a two-in-one fiber to provide the ideal join.

Programmable beam adjustment and monitoring

Also, some companies suggest employing programmable adjustment of the output beam mode and monitoring technology for the welding process. This improvement in laser technologies makes real-time feedback possible for significant processing characteristics.

Beam modes and material efficiency

The achievement of an accurate laser beam can be made through numerous beam modes to enhance the efficiency of coated steels, aluminum, and dissimilar materials. New fiber laser systems with continuous wave and quasi-continuous wave options offer more accuracy than conventional lasers.

Applications in industry

Fiber laser technology has multiple applications in the automotive, e-mobility, and electronics industries, and today it attracts more attention than before due to fiber lasers’ ability to weld in a short period and at the highest quality by tuning the intensity allocation of laser systems.

Two-in-one fiber technology

The new laser system includes a two-in-one fiber that consists of two fiber cores located coaxially. Each fiber core can be programmed to create a percentage of the laser’s power, for example, 40% to the inner fiber core and 60% to the outer core. In addition, the level of power tuning can achieve 1 percent precision in such a fiber laser.

Advantages of the new fiber laser system

The main advantages of the fiber laser system include spatter-free laser power allocation, which dramatically accelerates the process, and a changeable two-in-one fiber that can be quickly replaced by a new fiber in case of its damage, because these fibers are standard for fiber laser systems.

Comparison with CO2 lasers

Traditionally, CO2 lasers are used for welding processes in heavy industries because of their speed a level of quality. The new solid-state fiber laser system opens new possibilities for the industry because it allows welding stainless steel sheets and also tubes and profiles with a very high feed rate at good quality, almost without spatter.

Organic laser system diodes with low losses and electricity requirements

organic laser diodes

Research background: organic semiconductors in laser technology

Researchers from Japan confirm that it is possible to use laser technology for lasing by direct electrical stimulation of an organic film. Later, they demonstrated a laser system diode that is based on organic semiconductors. Traditionally, organic laser system diodes create pure light; higher magnitudes of currents are required than it is usually applied in OLEDs to provide the laser technology process.

Challenges in organic laser system diodes

It is quite difficult to obtain enough electrical charges in numerous organic materials because of their high level of resistance to electricity before the materials heat up and burn out. Most organic materials and laser system devices operating under high currents face different loss processes; consequently, the efficiency reduces and the necessary current up becomes higher.

Use of BSBCz material in laser technology

To resolve the mentioned issues and successfully present an organic laser system diode, it is required to apply a highly efficient organic light-emitting material (BSBCz) in the laser technology. The material offers comparatively low resistance to electricity and a low level of losses, even though huge amounts of electricity are injected. The design of the developed laser device includes a structure with a grid of insulating material on top of one of the electrodes, applied to inject electricity into the organic thin films.

Role of grids in laser performance

These grids or distributed feedback structures in laser system devices are able to create the optical effects required for laser technology. The optimization of the grids opens new possibilities and allows getting the required optical properties, as well as monitoring the electricity flow in the laser system devices, and reducing the amount of electricity necessary to supervise laser system processes from the organic thin film.

Testing and results of the improved technology

The improved laser technology has been tested concerning laser beam emission under current injection. The researchers confirm that the successful laser beam emission is connected with the clear separation of the lasing wavelength from significant absorption because of charge carriers and triplet excitons.

At the present time, researchers are overcoming the final obstacles that interfere with making the organic laser system diodes used in commercial applications. Also, they believe that the laser system device can find an application in biosensing, displays, health care, and optical communications.

Despite the fact that there are a lot of doubts in the community about whether it would be possible to realize an organic laser system diode, nonetheless, the laser technology of slowly chipping away at the different performance limitations with developed materials and new laser system device structures finally makes it real.

The difference between 3D and cutting laser systems

laser systems

Laser systems in the cutting industry

Over the last years, laser systems for the cutting industry have become the essential device for the vast majority of sheet metal fabricators. All the time, the most preferable tool for fast and precise cutting of almost any metal less than 1 inch (2.54 cm) thick is a CO2 laser that continues enlarging its fields of application.

3D laser systems and additive manufacturing

At the time when laser systems appeared in laboratories, scientists found another laser application. The development of ultraviolet lasers gave birth to additive manufacturing, called 3D printing. 3D laser systems are able to produce virtually all available materials.

Technology comparison: 3D vs cutting lasers

Despite the fact that the light from a laser beam is not the only technology enabled to cure, sinter, melt, or even join these various materials, it remains the leader. The technology of metal-based 3D printing is based on infrared fiber lasers with a wavelength of 1,070 nanometers, whereas conventional laser cutters are based on solid-state fiber or disk laser systems with a wavelength in the range of 1,030 to 1,080 nm.

Wattage differences between laser systems

In spite of the fact that the wavelengths are similar, the wattage differs. The average power of 3D laser systems is 500 watts, while fiber lasers for cutting can generate up to 6 kilowatts. If that type of laser were installed in a 3D system, it would burn a hole through the bottom of the device.

Versatility and tunability of modern laser systems

Laser power is just one parameter among numerous others. That is why today laser manufacturers tend to provide the versatility of laser systems. For example, they create great lengths that allow making laser products tunable (that can be adjusted to a range of materials).

3D laser system manufacturers employ advanced fiber optics and electronics for quick improvement of laser parameters, like makers of laser cutters do. At present, it is possible to produce spots of different sizes by changing the crystal orientation for quick scanning of huge areas inside the part and following the tracing of the outline.

Impact on part quality and build speed

All these changes provide better part quality and faster build speeds of fiber laser systems. The fact is that a small spot size is better than a large one because it offers a small melt pool and, consequently, less stress. However, it means that there are lower deposition rates produced by the laser system.

Balancing process stability and costs

It is necessary to find a balance between process stability and the cost of fiber lasers. Of course, it is highly difficult to make because of various factors such as layer thickness, powder grain size, powder delivery and application mechanisms, the reflectivity of the raw material, and assorted machine parameters, but the development of a high-beam-quality laser system is required.

The use of laser systems in illumination products

semiconductor laser systems

Principle of operation: LED vs semiconductor lasers

The operation principle of an LED and a traditional semiconductor laser system is practically the same, which means that light is emitted during the combination of electrons and holes. The main difference is that the light of LEDs is emitted in a narrow spectral range, while the light from semiconductor lasers is emitted in a single wavelength.

Emission wavelength and applications

The emission wavelength of devices depends on the materials used. Thus, semiconductor laser systems emit the wavelengths whose ranges vary from infrared to ultraviolet. The laser applications include such fields as fiber optic communication, barcode readers, disc readers, and laser printing, but the use of laser systems as an illumination product remained impractical up to now.

Resonant cavity in semiconductor lasers

Similar to conventional laser systems, semiconductor lasers have a resonant cavity to facilitate amplification; the cavity consists of two parallel planes, separated by a few hundred µm, that operate as mirrors to direct emitted photons back into the resonant cavity.

Comparison with LEDs

There are some similarities between traditional LEDs and semiconductor laser systems, for example, their source of power is a driver converting AC to DC; they both suffer from a drop in light output at increasing temperatures. Semiconductor lasers are not receptive to a “droop” process, during which the increase in drive current causes lower efficacy.

Advantages of laser-based headlamps

In spite of the fact that usual blue LEDs offer higher efficacy than semiconductor laser systems provide, this is so only at lower input currents. This is the reason why BMW company offers headlamps based on a laser system that makes them 10 times brighter than traditional LED headlamps and 30 percent more efficient.

Working principle of laser headlamps

The principle of the laser headlamps’ operation is based on the creation of white laser beams by reflecting semiconductor laser light around inside the headlamp body frame using accurately established mirrors, then focusing the laser beam through a phosphor-filled lens, producing a white light of high intensity.

Efficiency and future potential

Semiconductor laser systems can provide efficiencies of a hundred times or even more than that of traditional LEDs, allowing higher light output from the laser beam with smaller die sizes. The laser system still requires some improvements for future laser applications because of the extremely narrow emission cone (about 1-2 degrees).

Semiconductor laser systems will be applied in architectural illumination products for which a narrow, high-quality laser beam is advantageous. It is possible to place lighting for museums, galleries, retail spaces, and other settings in a small area instead of being spread throughout.

Hybrid fiber laser system advances precision manufacturing

laser micromachining

Role of micromachining in modern manufacturing

The process of fine details micromachining plays a very important role in high-volume manufacturing in various fields of laser application, such as consumer electronics, medical devices, and the automotive industry. Highly accurate laser systems allow for the production of tiny holes, fine cuts, and narrow scribes. For example, the production of a usual smartphone that has thousands of details requires making millions of drilled holes and accurately cutting parts with fiber lasers.

Accuracy and quality, high throughput, and a low cost per unit are required for micromachining these fine details. Although mechanical methods, for example, drilling, milling, sawing, and sandblasting, can be suitable in quality and offer minimal heat damage, there are some limits on the size and consistency of details.

Compared to mechanical and other methods, laser technology provides higher accuracy, smaller details, and improved consistency with no laser system wear. The achievement of the mentioned characteristics required great advances in laser technology that were achieved just in recent years.

Purposes of micromachining with fiber lasers

One of the purposes of micromachining by the laser system is considered to be the removal of only the required material, generally through the method of localized heating. At the same time, the fiber laser minimizes heating and damage. To achieve the required result, it is necessary to deliver high-quality irradiation from a near-perfect laser beam accurately to the target region.

High throughput

Shorter wavelengths and shorter pulse widths are important in achieving the results. Moreover, the second purpose of the micromachining process made by the laser system is the opportunity to reach high machining throughput. It should be noted that the increase of average output power in the fiber laser results in higher ablation rates, however, with certain limitations.

Solutions through pulse tailoring

A possible solution to the current problem is tailoring the pulse sequence produced by a laser beam, with pulse bursts and pulse shapes. The energy-time profile from the laser beam is able to be tailored and optimized for a certain material and its interaction with the fiber laser system light so that the incident energy can be employed almost entirely for material removal and not excess heating.

Cost considerations in micromachining

The laser system cost is considered to be a key factor for the micromachining industry. The cost increase from the fiber laser process for each manufactured detail is the most crucial figure that contains such parameters as amortization of the upfront laser system cost, cost of operation, lost productivity from downtime, and process yield.