Periodic Reporting for period 4 - kW-flexiburst (Ultrashort pulsed kW-class laser with unprecedented flexible GHz burst operation for high precision high-throughput industrial manufacturing)
Période du rapport: 2023-01-01 au 2024-06-30
The next generation of laser systems for material processing needs to deliver higher precision, throughput and, most importantly, extreme flexibility. Current ultrafast laser technology has demonstrated applicability for enabling high precision micromachining. However current throughput is not efficient enough for widescale industrial manufacturing. The parameters of existing lasers are not flexible enough to consistently work in the optimal conditions necessary to reach the highest precision while using all available laser power. The kW-flexiburst project aims to develop a disruptive laser technology to help overcome this critical barrier, which could enable the next generation of manufacturing in a range of industrial sectors.
To achieve the project goals, kW-flexiburst, which stands for Ultrashort pulsed kW-class laser, has developed a high-power laser delivering bursts of ultra-short pulses with unique features. The system parameters can be arbitrarily adjusted in terms of burst repetition rate, intra-burst repetition rate, number of pulses per burst, pulse duration. The consortium has reached 1kW of average power with pulse duration of 1.5 ps.
The kW-Flexiburst project has overall been very successful with a high impact. We succeeded in:
- reaching kW-class ultrafast laser source with several different configurations including GHz bursts with few and high number of pulses in the burst
- demonstrating extremely high aspect ratio drilling with GHz bursts and high-speed stealth dicing (0.5 m/s)
- fast engraving of cylindrical rollers at a speed of 1 m²/ 46 minute
- demonstrating ablation rates up to 100 mm3 per minute and 4000 holes per minute drilling rate and ceramic substrates. Laser turning of precision shaped holes and micro-components was also successfully demonstrated .
As direct outcomes, the project has generated the launch of two new products, two ambitious internal projects within industrial partners to follow-up with the projects promising results and a new startup. The research has led to several scientific and technological breakthroughs published in high-quality journals and one patent.
To achieve the project goals, kW-flexiburst, which stands for Ultrashort pulsed kW-class laser, has developed a high-power laser delivering bursts of ultra-short pulses with unique features. The system parameters can be arbitrarily adjusted in terms of burst repetition rate, intra-burst repetition rate, number of pulses per burst, pulse duration. The consortium has reached 1kW of average power with pulse duration of 1.5 ps.
The kW-Flexiburst project has overall been very successful with a high impact. We succeeded in:
- reaching kW-class ultrafast laser source with several different configurations including GHz bursts with few and high number of pulses in the burst
- demonstrating extremely high aspect ratio drilling with GHz bursts and high-speed stealth dicing (0.5 m/s)
- fast engraving of cylindrical rollers at a speed of 1 m²/ 46 minute
- demonstrating ablation rates up to 100 mm3 per minute and 4000 holes per minute drilling rate and ceramic substrates. Laser turning of precision shaped holes and micro-components was also successfully demonstrated .
As direct outcomes, the project has generated the launch of two new products, two ambitious internal projects within industrial partners to follow-up with the projects promising results and a new startup. The research has led to several scientific and technological breakthroughs published in high-quality journals and one patent.
The consortium has met all its objectives. It has developed a radically new pulse generator concept, which offers the opportunity to work at tunable GHz repetition rates while freely adjusting the burst parameters. This concept has been implemented as seeder to ultrafast laser amplifiers reaching 250 W and 1 kW after a thin-disk multipass amplifier together with high beam quality. Demonstrators were built with high-power laser prototypes and performance against state-of the art have been characterized.
The performance of high power, ultrafast laser sources with GHz burst has been successfully demonstrated and evaluated in relevant industrial applications, which require high throughput and high quality laser processing methods. The related applications significantly benefit from the high-average power and the tunable pulses provided by the kW-flexiburst system. The selected applications span a wide range of industrial fields from micro-structuring of metals, ceramics and other dielectrics, drilling of hard substrates and cutting of transparent materials. Each of them carries significant or even disruptive improvements of the related industrial production process by employing the kW-flexiburst laser technology in combination with the beam delivery concepts and process methods proposed by the project.
Overall, the kW-flexiburst has a very strong immediate socio-economic impact and carries potential for further future impact. The project has already generated the launch of two new high-added value products, two ambitious internal projects within industrial partners to follow-up with the projects promising results, as well as the launch of a new startup.
Overall, the kW-flexiburst has a very strong immediate socio-economic impact and carries potential for further future impact. The project has already generated the launch of two new high-added value products, two ambitious internal projects within industrial partners to follow-up with the projects promising results, as well as the launch of a new startup.