Periodic Reporting for period 1 - LAMPAS (High throughput Laser structuring with Multiscale Periodic feature sizes for Advanced Surface Functionalities)
Période du rapport: 2019-01-01 au 2020-06-30
The project LAMpAS endeavours to create a conceptual, organisational and technical platform, providing an innovative laser structuring process for the design of newly functionalized surfaces. To make this platform competitive, it is necessary to enhance the efficiency, flexibility and productivity of the process, which can be achieved by combining a high-power ultra-short laser source with advanced strategies and concepts for high-speed beam delivery. In addition, inspired by natural surfaces (shark skin, lotus leaves, morpho butterfly or gecko feet), LAMpAS will allow to create surface topographies with multi-scale elements with feature sizes in the micro- and nanometre ranges, allowing to obtain a huge number of functionalities such as antibacterial, self-cleaning properties, friction reduction, optical security functions and/or decorative effects. However, the use of high-power laser sources in structuring processes leads to heat accumulation effects which deteriorate the required surface functions. Therefore, a truly understanding of the laser beam interaction with materials as such power levels is fundamental for designing adequate strategies for surface functionalization. At the end of the project, LAMpAS will design and develop a new laser-based technology platform capable to generate bioinspired surfaces with exceptional properties at an industrial scale for a larger target customer group.
LAMpAS addresses the following two main user groups:
(i) End users of consumer goods regarding household applications as well as other products that will be evaluated during the realization of the project
(ii) Machine manufacturers who will use any of the developed subcomponents (Laser source, high-speed beam delivery scanner, In-line monitoring system)
The specific objectives are:
(i) Development of a high-power picosecond -laser source
(ii) Design and develop of a high-speed beam delivery system combining interference pattering with polygon-scanners
(iii) Development of in-line monitoring concepts to assess the functional performances
(iv) Construction, design and development of a laser system integrating the sub-elements into one technology platform
(v) Processing of product demonstrators with high performance requirements
(vi) Validation of the treated prototypes in relevant environments at a high technology readiness level
LAMpAS addresses the following two main user groups:
(i) End users of consumer goods regarding household applications as well as other products that will be evaluated during the realization of the project
(ii) Machine manufacturers who will use any of the developed subcomponents (Laser source, high-speed beam delivery scanner, In-line monitoring system)
The specific objectives are:
(i) Development of a high-power picosecond -laser source
(ii) Design and develop of a high-speed beam delivery system combining interference pattering with polygon-scanners
(iii) Development of in-line monitoring concepts to assess the functional performances
(iv) Construction, design and development of a laser system integrating the sub-elements into one technology platform
(v) Processing of product demonstrators with high performance requirements
(vi) Validation of the treated prototypes in relevant environments at a high technology readiness level
The key component to be developed in LAMpAS is a flexible, high-power, ultrashort-pulsed laser source. The goal parameters of the high-power laser system were agreed on by the LAMpAS partners, and a lab demonstrator of the multipass amplifier has been designed, manufactured and tested in a laboratory setup. The project was able to demonstrate over 1 kW of output power and sufficient beam quality, which is fundamental for producing interference patterns with high homogeneity. Further on, the multipass amplifier, combined with the seed stage will validate the laser parameters forthe integration in the LAMpAS demonstrator. This high-power ultrafast laser will enable micromachining applications with increased throughput.
One main objective of the project is to design and construct a suitable interference optics and a polygon scanner, which address the objective concerning the spatial period and feature size, spot size, scan field size and throughput. So far, a beam delivery system with an innovative approach has been designed, which addresses those demands. Furthermore, new cooling solutions were found in order to avoid heating of sensitive optical components. Much effort was focussed on the reduction of system height and weight for addressing the specifications of the machine.
A prototype of each in-line monitoring modules, the near-infrared based sensor and the Fast-Fourier Transform (FFT) module, were engineered and proved based on the different measurement procedures. The operation of the near-infrared based sensor unit was demonstrated by treating stainless steel samples using a picosecond pulsed laser source. By means of the infrared camera it was possible to detect in-line instabilities affecting the surface quality of the produced samples. With these produced samples, the feasibility of the FFT module was satisfactory evaluated. The images, captured by the FFT system, showed a possible classification of different surface conditions, which will permit to evaluate the stability of the laser process in real-time.
The project also focuses on the development of simulation models to support the process development. A simulation algorithm for the calculation of the ablation depth as well as heat accumulation was developed and validated with experimental results. The simulation was adapted first for thin stainless steel plates. All partners defined the specifications and the interfaces between the different sub-elements/modules that will have to compose the final laser system and a first prototype equipped with a low power laser sources was constructed.
Furthermore, the characterization methods for each desired property have been developed, including testing methodologies for studing the performance of the anti-fingerprint, easy to clean and decoration properties. Also a methodology was defined to evaluate anti-bacterial properties. In addition, the process-related requirements have been defined, taking into account not only the processing time, but also the quality requirements and connectivity to the production lines.
One main objective of the project is to design and construct a suitable interference optics and a polygon scanner, which address the objective concerning the spatial period and feature size, spot size, scan field size and throughput. So far, a beam delivery system with an innovative approach has been designed, which addresses those demands. Furthermore, new cooling solutions were found in order to avoid heating of sensitive optical components. Much effort was focussed on the reduction of system height and weight for addressing the specifications of the machine.
A prototype of each in-line monitoring modules, the near-infrared based sensor and the Fast-Fourier Transform (FFT) module, were engineered and proved based on the different measurement procedures. The operation of the near-infrared based sensor unit was demonstrated by treating stainless steel samples using a picosecond pulsed laser source. By means of the infrared camera it was possible to detect in-line instabilities affecting the surface quality of the produced samples. With these produced samples, the feasibility of the FFT module was satisfactory evaluated. The images, captured by the FFT system, showed a possible classification of different surface conditions, which will permit to evaluate the stability of the laser process in real-time.
The project also focuses on the development of simulation models to support the process development. A simulation algorithm for the calculation of the ablation depth as well as heat accumulation was developed and validated with experimental results. The simulation was adapted first for thin stainless steel plates. All partners defined the specifications and the interfaces between the different sub-elements/modules that will have to compose the final laser system and a first prototype equipped with a low power laser sources was constructed.
Furthermore, the characterization methods for each desired property have been developed, including testing methodologies for studing the performance of the anti-fingerprint, easy to clean and decoration properties. Also a methodology was defined to evaluate anti-bacterial properties. In addition, the process-related requirements have been defined, taking into account not only the processing time, but also the quality requirements and connectivity to the production lines.
The project will provide the European industry with a cost-effective and robust technology, capable of producing a broad range of functional surfaces on large areas at outstanding throughputs (over 1 m²/min). This technology will have a significant impact in several European enterprises, allowing them the lead in this key area of surface treatment. The project LAMpAS will deliver the full value chain for laser surface texturing and has access to demanding markets. In addition, in-line process control methods will be included to enable rapid feedback about the target topography as well as to control surface temperature during the laser process. LAMpAS plans to supply a concise, market‐ready product description and a business model that outlines cost reductions and overall socio technological advantages.
The key novelty of LAMpAS is a combination of high-power ultra-short pulse laser source with an innovative beam delivery system, in combination with in-line quality characterization of the generated bioinspired surface texture. In effect, LAMpAS will reduce the costs of manufacturing using the micro structured parts, not just maintaining the position in the market but increasing the market share, especially in new emerging countries that are demanding high innovative products at low price. Thus, LAMpAS will not only add a new dimension of knowledge on technical project data but strengthening industrial manufacturing based on ultrashort pulse lasers and extending its field of application by simultaneous improvement of precision and productivity.
The key novelty of LAMpAS is a combination of high-power ultra-short pulse laser source with an innovative beam delivery system, in combination with in-line quality characterization of the generated bioinspired surface texture. In effect, LAMpAS will reduce the costs of manufacturing using the micro structured parts, not just maintaining the position in the market but increasing the market share, especially in new emerging countries that are demanding high innovative products at low price. Thus, LAMpAS will not only add a new dimension of knowledge on technical project data but strengthening industrial manufacturing based on ultrashort pulse lasers and extending its field of application by simultaneous improvement of precision and productivity.