Periodic Reporting for period 2 - OPeraTIC (Boosting the adoption of Ultrashort Pulsed Laser large scale structuring with an agile, dexterous and efficient manufacturing platform)
Reporting period: 2023-10-01 to 2025-03-31
Laser technology is a recognized enabler for producing eco-friendly products and reduce harmful processes and effluents. Ultrafast laser surface modification can substitute acid etching, coatings, chemical processing or energy intensive processes, being attractive, but limited typically to small flat parts due to the limitation of the systems and the optics.
OPeraTIC aims to develop a modular manufacturing platform to boost the uptaking of Ultra Short Pulsed Lasers (USPL) in industrial applications, where they can make a significant difference for clean, efficient and precise surface treatment of large and complex surfaces. The consortium identified the System concept and design as the main barrier for current industrial ultrafast applications.
The project objectives are:
OBJECTIVE O1: MODULAR ARCHITECTURE FOR HIGH POWER LASER MICROSTRUCTURING
High precision and dexterity manipulator for efficient laser processing, and complete optical chain compatible with the large envelope robotic system, including low dispersion optical fibre.
OBJECTIVE O2: CLOSED-LOOP DIGITAL PIPELINE FOR MODULAR, RECONFIGURABLE AND FLEXIBLE USPL PRODUCTION LINE
Control strategies for high accuracy laser processing through combination of process, optics and motion control with quality sensors, and real time monitoring of the system and the process. Digital infrastructure to integrate process data, enabling multidirectional data flow. RAMI4.0 compatible distributed controller.
OBJECTIVE O3: MACHINE INTELLIGENCE FRAMEWORK FOR ZDM STRATEGIES
AI based machine learning capabilities for advanced control, through the deployment of edge devices operating close to the data sources, attaining 10 micron resolution in fully 3D envelops of over a cubic meter working volume. Reduced setup time and first-time-right processes considering sustainability and energy efficiency. AI based process parameter prescription, optimization and correction.
OBJECTIVE O4: DEMONSTRATE OPeraTIC APPROACH IN REAL-SCALE FOR THE MANUFACTURING OF LARGE, HIGH PRECISION COMPLEX COMPONENTS, BOOSTING RESULTS EXPLOITATION AND ENABLING EU INDUSTRY ADOPTION
Validation of the developments in high impact components from four different industry sectors: lighting, industrial tooling (automotive), aerospace and home appliances. System integration, process development and benchmarking of the industrial use cases. Evaluate specific economic, technical and sustainability advantages of USPL processes for the four demonstrators.
OPeraTIC aims to develop a modular manufacturing platform to boost the uptaking of Ultra Short Pulsed Lasers (USPL) in industrial applications, where they can make a significant difference for clean, efficient and precise surface treatment of large and complex surfaces. The consortium identified the System concept and design as the main barrier for current industrial ultrafast applications.
The project objectives are:
OBJECTIVE O1: MODULAR ARCHITECTURE FOR HIGH POWER LASER MICROSTRUCTURING
High precision and dexterity manipulator for efficient laser processing, and complete optical chain compatible with the large envelope robotic system, including low dispersion optical fibre.
OBJECTIVE O2: CLOSED-LOOP DIGITAL PIPELINE FOR MODULAR, RECONFIGURABLE AND FLEXIBLE USPL PRODUCTION LINE
Control strategies for high accuracy laser processing through combination of process, optics and motion control with quality sensors, and real time monitoring of the system and the process. Digital infrastructure to integrate process data, enabling multidirectional data flow. RAMI4.0 compatible distributed controller.
OBJECTIVE O3: MACHINE INTELLIGENCE FRAMEWORK FOR ZDM STRATEGIES
AI based machine learning capabilities for advanced control, through the deployment of edge devices operating close to the data sources, attaining 10 micron resolution in fully 3D envelops of over a cubic meter working volume. Reduced setup time and first-time-right processes considering sustainability and energy efficiency. AI based process parameter prescription, optimization and correction.
OBJECTIVE O4: DEMONSTRATE OPeraTIC APPROACH IN REAL-SCALE FOR THE MANUFACTURING OF LARGE, HIGH PRECISION COMPLEX COMPONENTS, BOOSTING RESULTS EXPLOITATION AND ENABLING EU INDUSTRY ADOPTION
Validation of the developments in high impact components from four different industry sectors: lighting, industrial tooling (automotive), aerospace and home appliances. System integration, process development and benchmarking of the industrial use cases. Evaluate specific economic, technical and sustainability advantages of USPL processes for the four demonstrators.
The second period of the project concentrated in the definition of the OPeraTIC system architecture, at hardware, software and data level, and the specification of a complete platform including laser optical path, motion system and motion control. After this work, project partners developed a number of individual components for the OPeraTIC system, taking into account their integration. Advanced versions of the different components and modules were delivered as follows:
- Laser Source: High energy (1 mJ, 100W) picosecond IR laser, including advanced pulse-to-pulse triggering with sub-20 ns jitter and pulse/train on demand capabilities, with electronics responsive up to 50 MHz bandwidth.
- Optical Fibre: prototype for the fibre and beam launching system (BLS), demonstrated to be able to transmit femtosecond pulses with high energy (up to 1mJ for 300 fs pulses), and a Polarization Maintaining version able to transmit up to >200µJ pulses keeping predictable linear polarization with <30% losses.
- Beam Shaping modules: DLIP module (interference patterning) providing several millimetres in Depth of Focus, facilitating the usage on curved and complex 3D surfaces. DLW module consisting of an optical setup with an LCoS-SLM optical engine to be combined with industrial class collimators and galvoscanners, to produce custom energy distribution on demand in a robust and automated fashion.
- Robotic manipulator: robust, large volume (1m3), large area (>1m2) working space robotic system, including a novel motion controller programmed from scratch for dynamically corrected interpolated seven axis (five physical plus two optical axis) motion for on-the fly laser processing on large 3D surfaces.
- Beam and process monitoring system for DLIP and DLW, detecting beam quality issues, misalignments and other optical path deviations. Diffractographic and scatterometric quality control tool.
- Machine-level logical and data components, including Asset Administration Shell, full implementation of a Middleware for data handling, storage, serving, visualization and processing, and all required connectors for signal and information exchange in the system.
- AI models and algorithms able to train with a minimal amount of test data, thanks to a base training with synthetic information obtained through Physically Informed models, plus a Transfer Learning strategy. From those models and algorithms, predictive, prescriptive and corrective capabilities will augment the machine control to implement FTR and ZDM production strategies.
- Laser Source: High energy (1 mJ, 100W) picosecond IR laser, including advanced pulse-to-pulse triggering with sub-20 ns jitter and pulse/train on demand capabilities, with electronics responsive up to 50 MHz bandwidth.
- Optical Fibre: prototype for the fibre and beam launching system (BLS), demonstrated to be able to transmit femtosecond pulses with high energy (up to 1mJ for 300 fs pulses), and a Polarization Maintaining version able to transmit up to >200µJ pulses keeping predictable linear polarization with <30% losses.
- Beam Shaping modules: DLIP module (interference patterning) providing several millimetres in Depth of Focus, facilitating the usage on curved and complex 3D surfaces. DLW module consisting of an optical setup with an LCoS-SLM optical engine to be combined with industrial class collimators and galvoscanners, to produce custom energy distribution on demand in a robust and automated fashion.
- Robotic manipulator: robust, large volume (1m3), large area (>1m2) working space robotic system, including a novel motion controller programmed from scratch for dynamically corrected interpolated seven axis (five physical plus two optical axis) motion for on-the fly laser processing on large 3D surfaces.
- Beam and process monitoring system for DLIP and DLW, detecting beam quality issues, misalignments and other optical path deviations. Diffractographic and scatterometric quality control tool.
- Machine-level logical and data components, including Asset Administration Shell, full implementation of a Middleware for data handling, storage, serving, visualization and processing, and all required connectors for signal and information exchange in the system.
- AI models and algorithms able to train with a minimal amount of test data, thanks to a base training with synthetic information obtained through Physically Informed models, plus a Transfer Learning strategy. From those models and algorithms, predictive, prescriptive and corrective capabilities will augment the machine control to implement FTR and ZDM production strategies.
A first full implementation of a Middleware for laser micromachining tools and the Asset Administration Shell for the prototype machine was delivered, posing one of the very first RAMI4.0 compatible digital architectures for laser micromachining systems.
A complete beam coupling, transmission and outcoupling system, based on a photonic crystal optical fibre, designed for high energy USPL (1mJ) was demonstrated, being a foundation for the robotic processing of 3D surfaces. A Polarization Maintaining version with its own BLS was delivered, based on consistently induced linear birefringence, requiring further work to increase the energy bearing capacity to >200 µJ levels.
A large depth of focus DLIP (several mm) was delivered to provide a robust processing with reduced requirements on the motion system and better adaptability to curved surfaces, based on a novel combination of refractive and diffractive optics.
A combination of linear actuators, angular positioners and optical axis (scanners), with high energy bearing SLM modules, was assembled in a powerful test bed with automated adjustment of positions and parameters, for the generation of large volumes of data for AI training.
A powerful Transfer Learning AI model was developed and demonstrated to reduce the volume of test data required to train a predictive AI model for laser processing, producing reliable prescriptions of process parameters with smaller test database, when confronted with a new material, optics or processing conditions, increasing usability in real industrial environments.
Developments in laser processes: USPL microdimple patterns demonstrate advantages in tribological 3D surfaces for deep drawing tools. Parallel processing on mould steel demonstrated robust formation of Superhydrophobic surfaces on the tool, and Superhydrophobic surfaces on the replicated polymer. Anti icing surfaces were produced on finished (painted/coated) composite components for aerostructures.
A complete beam coupling, transmission and outcoupling system, based on a photonic crystal optical fibre, designed for high energy USPL (1mJ) was demonstrated, being a foundation for the robotic processing of 3D surfaces. A Polarization Maintaining version with its own BLS was delivered, based on consistently induced linear birefringence, requiring further work to increase the energy bearing capacity to >200 µJ levels.
A large depth of focus DLIP (several mm) was delivered to provide a robust processing with reduced requirements on the motion system and better adaptability to curved surfaces, based on a novel combination of refractive and diffractive optics.
A combination of linear actuators, angular positioners and optical axis (scanners), with high energy bearing SLM modules, was assembled in a powerful test bed with automated adjustment of positions and parameters, for the generation of large volumes of data for AI training.
A powerful Transfer Learning AI model was developed and demonstrated to reduce the volume of test data required to train a predictive AI model for laser processing, producing reliable prescriptions of process parameters with smaller test database, when confronted with a new material, optics or processing conditions, increasing usability in real industrial environments.
Developments in laser processes: USPL microdimple patterns demonstrate advantages in tribological 3D surfaces for deep drawing tools. Parallel processing on mould steel demonstrated robust formation of Superhydrophobic surfaces on the tool, and Superhydrophobic surfaces on the replicated polymer. Anti icing surfaces were produced on finished (painted/coated) composite components for aerostructures.