Periodic Reporting for period 1 - LaserWay (Extremely High-Speed Laser Processes For Sustainable And Flexible Manufacturing)
Berichtszeitraum: 2024-01-01 bis 2025-06-30
The LaserWay project is set to transform the manufacturing landscape by replacing conventional, inefficient, and environmentally damaging methods with agile, high-speed laser-based production lines. The initiative focuses on three cutting-edge laser technologies: laser blanking, laser micro-drilling, and extreme high-speed laser material deposition (EHLA) chosen for their potential to enable more sustainable, precise, and adaptable manufacturing processes.
At the heart of the project is the development of WayFASTER machines, designed to elevate the performance of these laser technologies. These machines incorporate lightweight structural designs, advanced vibration control, and optimized programming tailored for high-speed laser operations. Complementing this, WayBETTER Photonics ensures precise and reliable laser beam delivery at extreme processing speeds, addressing the distinct requirements of each laser application.
To further boost efficiency and sustainability, the WaySTRONGER integration concept combines mechanical and digital innovations to seamlessly embed these technologies into existing manufacturing ecosystems. This approach enhances the resilience, flexibility, and eco-efficiency of modern production lines.
To achieve the project’s main goal, the fulfilment of the following specific objectives is required:
• Objective 1: To develop machines for extremely high-speed 2D applications.
• Objective 2: To maintain the gap between the laser nozzle and the metallic part at extremely high-speed.
• Objective 3: To program smoother tool paths for high-speed movements.
• Objective 4: In-process control at high-speeds to avoid downtime related to quality issues.
• Objective 5: To provide a sustainable alternative to conventional processes.
• Objective 6: To demonstrate and validate the project solutions
At the heart of the project is the development of WayFASTER machines, designed to elevate the performance of these laser technologies. These machines incorporate lightweight structural designs, advanced vibration control, and optimized programming tailored for high-speed laser operations. Complementing this, WayBETTER Photonics ensures precise and reliable laser beam delivery at extreme processing speeds, addressing the distinct requirements of each laser application.
To further boost efficiency and sustainability, the WaySTRONGER integration concept combines mechanical and digital innovations to seamlessly embed these technologies into existing manufacturing ecosystems. This approach enhances the resilience, flexibility, and eco-efficiency of modern production lines.
To achieve the project’s main goal, the fulfilment of the following specific objectives is required:
• Objective 1: To develop machines for extremely high-speed 2D applications.
• Objective 2: To maintain the gap between the laser nozzle and the metallic part at extremely high-speed.
• Objective 3: To program smoother tool paths for high-speed movements.
• Objective 4: In-process control at high-speeds to avoid downtime related to quality issues.
• Objective 5: To provide a sustainable alternative to conventional processes.
• Objective 6: To demonstrate and validate the project solutions
Significant progress has been made in the development and validation of new laser-based manufacturing technologies during the first phase of the LaserWay project. Key achievements are summarized below:
1. Machine and Laser Head Development
New designs for laser machines and heads have been finalized, laying the foundation for experimental validation in the second project period. A dedicated laser blanking machine and a novel EHLA 3D system have been fully designed and will be manufactured in the upcoming phase. These innovations are protected by two patent applications related to the new machine concepts.
2. Gap Control Enhancements
Gap control is a critical aspect for both laser blanking and micro-drilling processes. In both use cases, major improvements have been achieved in increasing the sampling frequency of the gap sensor and in enhancing the vertical positioning accuracy of the laser head. These improvements are expected to ensure higher process stability and precision, particularly under high-speed operation.
3. Process Monitoring Systems
Advanced monitoring strategies have been defined for all three targeted processes (laser blanking, micro-drilling, and EHLA), enabling the identification of optimal process windows to meet the ambitious speed and quality targets of LaserWay. Specific developments include:
• For laser micro-drilling, a scattered light-based monitoring system and an in-process vision system to assess hole quality directly on the machine.
• For EHLA, a comprehensive monitoring setup for melt pool temperature, stability, and standoff distance control.
• For laser blanking, monitoring solutions for piercing stability and coil edge positioning.
4. Dynamic Beam Shaping for Micro-Drilling
To counteract the deformation of holes due to high-speed movements, dynamic beam shaping has been introduced as a key innovation. Two approaches have been developed:
• Integration of a galvo scanner into the drilling head
• Use of a fast-steering mirror for beam trajectory compensation
These solutions should help preserving the circularity and quality of holes at high feed rates.
1. Machine and Laser Head Development
New designs for laser machines and heads have been finalized, laying the foundation for experimental validation in the second project period. A dedicated laser blanking machine and a novel EHLA 3D system have been fully designed and will be manufactured in the upcoming phase. These innovations are protected by two patent applications related to the new machine concepts.
2. Gap Control Enhancements
Gap control is a critical aspect for both laser blanking and micro-drilling processes. In both use cases, major improvements have been achieved in increasing the sampling frequency of the gap sensor and in enhancing the vertical positioning accuracy of the laser head. These improvements are expected to ensure higher process stability and precision, particularly under high-speed operation.
3. Process Monitoring Systems
Advanced monitoring strategies have been defined for all three targeted processes (laser blanking, micro-drilling, and EHLA), enabling the identification of optimal process windows to meet the ambitious speed and quality targets of LaserWay. Specific developments include:
• For laser micro-drilling, a scattered light-based monitoring system and an in-process vision system to assess hole quality directly on the machine.
• For EHLA, a comprehensive monitoring setup for melt pool temperature, stability, and standoff distance control.
• For laser blanking, monitoring solutions for piercing stability and coil edge positioning.
4. Dynamic Beam Shaping for Micro-Drilling
To counteract the deformation of holes due to high-speed movements, dynamic beam shaping has been introduced as a key innovation. Two approaches have been developed:
• Integration of a galvo scanner into the drilling head
• Use of a fast-steering mirror for beam trajectory compensation
These solutions should help preserving the circularity and quality of holes at high feed rates.
LaserWay have contributed to the state of the art with the following scientific publications:
1. Highly dynamic croXY crossed linear rail gantry design, 18th International Conference on High Speed Machining. Submitted.
2. Process planning for high-speed coil fed laser cutting with two laser heads, 18th International Conference on High Speed Machining. Submitted.
3. Fundamentals of active vibration damping via load-side motion feedback in machine tool feed drives, 18th International Conference on High Speed Machining. Submitted.
4. Two stage feedrate optimization using analytical jerk gradients and a time minimizing objective function, 18th International Conference on High Speed Machining. Submitted.
5. Esmoris et al. [2025], High speed single pulse microdrilling strategies for the reduction of distorsions and defects in micro-hole density metal panels, 18th International Conference on High Speed Machining. Submitted.
6. Data-driven feedforward control of inertial dampers for accuracy improvement, CIRP Annals 73 (1), 317-320
1. Highly dynamic croXY crossed linear rail gantry design, 18th International Conference on High Speed Machining. Submitted.
2. Process planning for high-speed coil fed laser cutting with two laser heads, 18th International Conference on High Speed Machining. Submitted.
3. Fundamentals of active vibration damping via load-side motion feedback in machine tool feed drives, 18th International Conference on High Speed Machining. Submitted.
4. Two stage feedrate optimization using analytical jerk gradients and a time minimizing objective function, 18th International Conference on High Speed Machining. Submitted.
5. Esmoris et al. [2025], High speed single pulse microdrilling strategies for the reduction of distorsions and defects in micro-hole density metal panels, 18th International Conference on High Speed Machining. Submitted.
6. Data-driven feedforward control of inertial dampers for accuracy improvement, CIRP Annals 73 (1), 317-320