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The first step on the roadmap of parallel processing for cylinder embossing dies was realized with an eight- spot processing head based on ns-fiber laser with passive optical beam splitting, individual spot switching by acousto optical modulation and an advanced imaging. Patterning of cylindrical embossing dies shows a high efficiency of nearby 80%, diffraction-limited and equally spaced spots with pitches down to 25μm achieved by a compression using cascaded prism arrays. Due to the nanoseconds laser pulses the ablation shows the typical surrounding material deposition of a hot process.
In the next step the processing head was adapted to a picosecond-laser source and the 500W fiber laser was replaced by an ultrashort pulsed laser with 300W, 12ps and a repetition frequency of up to 6MHz. This paper presents details about the processing head design and the analysis of ablation rates and patterns on steel, copper and brass dies. Furthermore, it gives an outlook on scaling the parallel processing head from eight to 16 individually switched beamlets to increase processing throughput and optimized utilization of the available ultrashort pulsed laser energy.
One challenge for ultra-fast micro machining is throughput. The operational capacity of these processes can be maximized by increasing the scan rate or the number of beams – parallel processing. This contribution focuses on process parallelism of ultra-short pulsed lasers with high repetition rate and individually addressable acousto-optical beam modulation. The core of the multi-beam generation is a smooth diffractive beam splitter component with high uniform spots and negligible loss, and a prismatic array compressor to match beam size and pitch. The optical design and the practical realization of an 8 beam processing head in combination with a high average power single mode ultra-short pulsed laser source are presented as well as the currently on-going and promising laboratory research and micro machining results. Finally, an outlook of scaling the processing head to several tens of beams is given.
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