Anton Pauli, CEO, GFH, and Maik Frede, CEO, neoLASE
The demand for components of high quality in large quantities and the shift of value chains to regions with low production costs are putting competitive pressure on many manufacturing operations. Often, the only way to absorb this is through faster manufacturing methods. This requires modern technologies that afford a high degree of automation but are typically out of reach for small to midsize enterprises (SMEs) in particular. Frequently, procurement costs for equipment such as ultra-short pulse (USP) laser micromachining systems, are simply too high.
GFH and neoLASE have jointly developed a cost-effective solution under the European Union (EU) subsidy programme Horizon 2020, namely the Smart Modular All-in-One Robust Laser Machining Tool (SMAART), a highly flexible, fully automated ultrashort pulse (USP) laser machining technology that automatically switches between various process steps such as laser turning and fine texturing using an especially programmed intelligent control unit. SMAART covers a pulse range of 500 ps to 500 fs and eliminates the need for complex changeovers. This keeps the acquisition cost down and is intended to increase product quantities and create jobs over the long term.
As production or personnel costs go up, many operations are forced to restructure their production processes or to outsource them entirely. Countries outside the EU that have lower wages and operating costs are especially attractive to German companies in this context. This means Europe loses a significant amount of potential sales and added value. In order to counteract this trend, the EU is promoting the development of new technologies to make production processes more efficient and therefore cost-effective through initiatives and tender offers such as its Horizon 2020 funding programme.
GFH and neoLASE’s SMAART is one of many projects that has been part-financed by Horizon 2020. The focus of this project has been making it possible to deliver high precision components through contactless and therefore gentler USP laser techniques.
Conventional laser micromachining systems are not only very expensive, but their structure is complex and they are limited to single production steps. This means that different systems are often needed for different manufacturing methods or that complex and time-consuming changeovers are required. Furthermore, extensive know-how of the systems’ laser technologies is likely to be a requisite for optimal results.
GFH and neoLASE developed SMAART for integration into GFH’s GL series of laser micromachining systems, to enable appropriate laser selection (picosecond or femtosecond laser) according to the component material and process via the input interface, as well as generation of the correct process parameters. As a result, the systems afford high efficiency and broad production scope, yet comprehensive, specialised knowledge in the field of laser machining is not required for their operation.
The first step of the project involved precisely defining the challenges, market situation, technical status quo and required development steps. To make the implementation of such a project possible, the technology needed to be made accessible to the customer and more simplistic.
A flexible amplifier design enables variable pulse duration and performance classesA universal, compact USP laser source is used for the rapid, automated adaptation of the pulse duration and intensity required to enable switching between various process steps and laser parameters without changeovers. Furthermore, the GL machines incorporate an intelligent control unit that automatically identifies the respective parameters and components for the individual machining steps, so there is no need for an operator to calculate these in advance and manually enter them.
The control unit is supplied by neoLASE and features the company’s generic amplifier platform (GAP) module. The flexible design of the module means that different pulse durations and performance classes can be called up on the machines without the need for chirped pulse or regenerative amplifiers. This has made it possible for the machines to have a more compact layout yet still generate pulse energies of up to 400 µJ and achieve an average output of 80 W. Additional costs due to more complex lasers or components are thus avoided. GFH generally designs its machines around modularity and flexibility, making them ideal candidates for the GAP module.
As the compact laser source and GAP module combined afford a pulse range from 500 ps to 500 fs and fast switching is guaranteed, the GL machines are able to deliver significant speed increases and quality improvements. Further optimisation of the removal rate is conceivable through the simultaneous use of picosecond and femtosecond pulses.
Contactless laser micromachining can replace energy-intensive processesContactless laser micromachining also contributes to speed increases and quality improvements. Specifically, the pulses are so short that there is no noteworthy thermal conduction, meaning that melting of the material, microstructure changes, phase changes and thermal stresses in the component are avoided. This opens up a broad field of applications for the production of microcomponents, not only in classic mechanical engineering but also various industries such as medical technology, textile and watchmaking.
The ideal scenario is that energy-intensive or ecologically questionable processes are replaced. This is particularly important if the objective is to produce consistently high-quality components in large quantities without increasing production costs.
A process parameter database and online quality control tool contribute to ease of useThe GL machines have a database of various process parameters such as pulse duration, traverse path of the optics, component dimensions and type of material, allowing for a high level of flexibility from the outset. This makes it possible to choose from over 100 manufacturing methods for drilling, cutting, texturing and material removal for metal, ceramics, glass and polymers via the input interface. The user initiates the desired process step at the push of a button, then the machine is positioned in the same mounting. If new applications or process parameters that have not been defined are added, the machine and GAP module are correspondingly adapted. This means that SMAART is subject to continuous learning and development.
The machines also feature an online quality control tool that validates the process parameters during machining, thus ensuring consistently high-quality components, even in the case of difficult to process materials such as diamond. The tool makes quality sampling possible, even as the process step is being executed.
GFH
NeoLASE
Image 1: The GL.compact II laser micromachining system. Thanks to the flexible amplifier design of the generic amplifier platform (GAP) module from neoLASE, different pulse durations and performance classes can be called up on GFH’s GL series of laser micromachining systems without the need for chirped pulse or regenerative amplifiers.
Image 2: A neoLASE neoMOS ultrashort pulse (USP) laser. Modular laser technology in the smallest possible space makes compact, flexible laser micromachining systems possible.
Image 3: A laser turned carbide part with holes that was produced using a GL series micromachining system.