Project: Next-Generation Ultrafast Lasers and Workstations for Industrial Materials Processing
While laser processing of materials using continuous wave and q-switched (nanosecond) lasers is well known in industry, the application of pico- and femtosecond laser systems has until recently been restricted to niche applications by the lack of high-power and high repetition rate laser systems with industrial reliability. However, countless scientific studies have shown the possibility to employ ultrashort optical pulses for defining, fabricating and modifying materials on dimensional scales now reaching nanometers in a wide range of materials. _x000D_ In order to move the scientific results from universities into actual production facilities, high speed, high average power laser systems, mechanically and electronically integrated with suitable scanning systems are necessary. For this purpose the NEPWARP project was started. After approximately two third of the approved time, and the results of the work packages 1, 2 and 3, it has become clear that within the reCOing time the originally targeted output power of the new laser systems will not be reached by HQI. HQI still has long term objectives to reach the above stated specifications, but for the reCOder of the project we have to define new, realistic objectives._x000D_ _x000D_ HQI plans to further improve an already existing fiber based amplifier using technology developed by IQO as part of work package 3, and HQI plans to develop a femtosecond laser prototype using technology developed in work package 1._x000D_ IQO plans to continue supporting HQI in the development of fiber-based laser systems._x000D_ GFH plans to replace the laser system HQI is unable to deliver within the original project plan with a system from an external supplier, and then continue application development._x000D_ HQI and GFH will continue to co-develop electronic and mechanical interfaces._x000D_ _x000D_ The new objectives are to_x000D_ - develop next generation ultrafast high power laser systems for material processing applications employing pico- and/or femtosecond pulses with powers exceeding 20W at up to 3MHz pulse repetition rate._x000D_ - develop novel methods of ultrafast amplifiers and generators in order to generate laser pulses exceeding 20µJ/pulse at 1MHz repetition rate. _x000D_ - develop advanced synchronisation methods between the laser, beam scanners and fast and precise motion control systems. _x000D_ - develop novel high voltage switching circuitry to enable laser developments in the proposed and other fields._x000D_ - utilise femtosecond and picosecond ultrafast lasers in an advanced materials processing system suitable for high speed processing._x000D_ - increase the throughput for large scale industrial laser micro-processing._x000D_ - demonstrate economic and efficient processing of surface microstructures and 3D geometries_x000D_ - convert the IR-laser wavelength into other spectral regions in order to explore optimisation opportunities with these laser parameters_x000D_ _x000D_ Consortium_x000D_ The SME HQI has 10 years of experience in the development of ultrafast lasers. Key technologies for the fabrication of ultrafast laser systems, like Semiconductor Saturable Absorber Mirrors (SESAMs) for modelocking, utilisation of bulk crystals, design of multi-crystal resonators and regenerative amplifiers and others are available to HQI. It has recently introduced ultrafast laser systems exceeding 30W average power and has shown a first fiber based demonstrator using technology developed during the project. HQI expects to be able to further scale the output power of the demonstrator using technology developed by a consortium member (IQO). Based on the results of workpackage 1 HQI will build a prototype femtosecond regenerative amplifier exceeding 20W output power and repetition rates exceeding one MHz._x000D_ _x000D_ Within the project, IQO will evaluate riskier and less proven, but potentially more cost effective, technologies for their suitability within an industrial system. IQO will further provide support on all basic science issues for the participating SMEs. This will include the evaluation of fibre based technologies but also advanced approaches employing bulk laser crystals as well as frequency conversion techniques and their implementation related to material processing._x000D_ _x000D_ GFH has been working in the laser microprocessing area since its start in 2000. Nanosecond and picosecond lasers are utilised for machining of high precision microholes, microstructures and 3D geometries. A 5-axis-micromachining system has been developed and is currently in the realisation phase._x000D_ GFH will provide HQI with important information on system interfacing and both companies will work closely towards the development of suitable control electronics to seamlessly integrate the new laser system in the final 5-axis processing station. GFH will also develop enhanced machining strategies, processing software, algorithms and an initial process database for workstation integration._x000D_
| Acronym | NEOWARP (Reference Number: 4589) |
| Duration | 01/09/2009 - 31/07/2012 |
| Project Topic | NEOWARP addresses the future need for high-power and flexible pico- and femtosecond lasers for industrial materials processing through novel laser concepts and technologies. Processing know-how, workstation interfacing, integration, machining strategies and algorithms will be improved. |
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Project Results (after finalisation) |
The intent of NEOWARP was to develop a new class of laser systems with a significant increase in available laser power and pulse energy; deliver prototypes of those systems to the participants and develop new applications for such systems. Due to technical reasons the originally intended solutions did not allow access to higher power levels without significant problems, like high sensitivity to tolerances, prohibiting transfer of this technology to a production environment. This resulted in a change request for the project and we were allowed to continue working on alternative solutions. We are currently in the process of transferring this solutions from R&D to our production and intend to introduce a new laser system with 16 W output power this summer - a increase in power by a factor of 2 compared to the existing products at start of the project._x000D__x000D_Apart of the technical achievements NEOWARP allowed us access to knowledge and information from the project Ps not available otherwise._x000D_ |
| Network | Eurostars |
| Call | Eurostars Cut-Off 2 |
Project partner
| Number | Name | Role | Country |
|---|---|---|---|
| 3 | GFH GmbH | Partner | Germany |
| 3 | High Q Laser Innovation GmbH | Coordinator | Austria |
| 3 | Institut of Quantum Optics, University of Hannover | Partner | Germany |