Dr Jack Gabzdyl Product Line Manager Pulsed Lasers

Size: px

Start display at page:

Download "Dr Jack Gabzdyl Product Line Manager Pulsed Lasers"

Shonda Henry
5 years ago
Views:

1 AILU PHOTONEX th October 2008 Fiber Lasers for Medical Applications Dr Jack Gabzdyl Product Line Manager Pulsed Lasers General Advantages of Fibre Lasers Beam Quality & Stability Diffraction-limited beam Small spot size (<10um possible) No pointing drift nor thermal lensing problems Flexible beam delivery All Fiber Integrated: No free space optics to adjust / tune Zero-maintenance solid-state system Compact and easy to integrate Operational Benefits Low-power consumption (wall-plug efficiency) No gases required No consumable items Fewer support specialists 1

R4 High Power Laser 25-200W Air Cooled 100-400W Water Cooled Features - CW or Modulated to 100 khz (modulated pulses <5µs to CW)

5% output power variation) G3 Pulsed laser range Features of 10 & 20 W/RM, 12 & 20W/HS and 30W/HM Features - Up to 500 khz pulse

2 R4 High Power Laser W Air Cooled W Water Cooled Features - CW or Modulated to 100 khz (modulated pulses <5µs to CW) -TEM 00 (M² <1.1), <BPP 0.37 mm.mrad - Central Emission Wavelength: 1070 ± 10nm -High stability laser (typically <±0.5% output power variation) G3 Pulsed laser range Features of 10 & 20 W/RM, 12 & 20W/HS and 30W/HM Features - Up to 500 khz pulse repetition frequency - Pulsed and CW operation - Pulse width variable (across 25 pre-set waveforms) - Peak Emission Wavelength: 1064 ± 5 nm 2

$mrad CLM 1550/1565nm Features - Up to 20W optical output power - Diffraction limited to beam quality (M2<1.1) Why a Fibre Laser?$

3 Compact Laser Module 1090/1550/1565nm CLM 1090nm Features -CW or Modulated to 50kHz (modulated pulses 10µs to CW) - TEM00 (M² <1.1), BPP 0.38 mm.mrad CLM 1550/1565nm Features - Up to 20W optical output power - Diffraction limited to beam quality (M2<1.1) Why a Fibre Laser? Key differentiators vs YAG/CO2 Size Common 5U 19 Rack format Performance Power Stability & Linearity Modulation & Control Range Beam Quality Total Cost of Ownership No scheduled maintenance interval Energy Efficiency 3

Performance : Beam Quality Application: Ceramic

ownership Fibre Lasers vs YAG Lasers Fibre Laser

Maintenance Interval None 500-1000 Hours ( Lamp

path requires frequent adjustment Regular

replacement of diode packs Diode pack maintenance

mirrors Consumable items None Lamps : $100-200

average costs) Power Consumption Single phase

4 Performance : Beam Quality Application: Ceramic scribing Fibre Laser λ=1.07um, M2<1.1 CO2 Laser λ=10.6um, M2~1.3 M 2 < W Fibre Laser 400W CO2 Laser Total cost of ownership Fibre Lasers vs YAG Lasers Fibre Laser Lamp pumped YAG Diode Pumped YAG Scheduled Maintenance Interval None Hours ( Lamp Pumped) 10,000 Hours ( Diode Pumped ) Optical path requires frequent adjustment Regular replacement of flashlamps Periodic maintenance/ replacement of diode packs Diode pack maintenance Cleaning replacement and alignments of lenses and mirrors Consumable items None Lamps : $ each Diode Packs : $ each (Note: average costs) Power Consumption Single phase Single/3Phase 15-20% WPE 2-10% WPE Chiller Not required for < 200W Cost $4000-$8000 Replacement period ~ 24months 4

5 Output power stability 200W Laser over full operating temperature range C SP-200C-0004 Active Cycle Started 11 March :29:25 Ended 12 March :59:25 Pow er_(w) Set_Temp Act_Temp Delta Power = 0.40W (± 0.1 %) Power (W) Temp ( C) Time (hrs) Pulse to pulse stability Pulse Energy Distribution for 10Hz, 50msec pulses at 100W No. Pulses Pulse Energy (mj) Avg 4.857J Min 4.832J Max 4.882J Sigma 0.007J 68.26% of all pulses are within ±0.007J of 4.857J (0.15%) 95.46% of all pulses are within ±0.014J of 4.857J (0.31%) 99.73% of all pulses are within ±0.021J of 4.857J (0.46%) 5

6 High modulation rate 200W Laser at 100kHz, 50% Duty cycle Pulse shape of 200W laser at frequency of 100kHz and 50% duty cycle Signal (arb) Trigger Signal Time (us) Medical Applications Materials processing Cutting Welding Rapid Prototyping Marking Therapeutic Medical Aesthetics ti 6

Fine tube Cutting Wide range of tubes and needles used in

can be other metals Fine features required High part

tube cutting Cutting highly detailed Coronary Stents High

to be achieved for thin materials Cutting speeds with

rates of a few khz The direct modulation capability up to

cutting process development Productivity improvements >5x

7 Fine tube Cutting Wide range of tubes and needles used in medical applications Predominantly stainless steel but can be other metals Fine features required High part accuracy No burrs Micromachining Thin metal sheet and tube cutting Cutting highly detailed Coronary Stents High beam quality allows very fine kerf as low as 10um widths to be achieved for thin materials Cutting speeds with conventional solid state lasers are limited by repetition rates of a few khz The direct modulation capability up to 100kHz of SPI s CW-M fibre lasers allows high speed cutting process development Productivity improvements >5x in cutting speeds have been demonstrated by fibre lasers in these applications 7

Growing use of laser welding in medical device manufacture Laser welding provides High

control Ability to weld small and thin parts Ability to weld wide range of metallic

the Fibre laser is becoming the laser of choice Comparable Nd:YAG weld Can clearly l see

8 Growing use of laser welding in medical device manufacture Laser welding provides High quality joints Repeatable process High accuracy High reliability Process that is in control Ability to weld small and thin parts Ability to weld wide range of metallic materials Welding of dissimilar materials Traditionally Nd:YAG systems were used but now the Fibre laser is becoming the laser of choice Comparable Nd:YAG weld Can clearly l see the overlapping spot welds in this pulsed seam weld Typical pulsed YAG weld in stainless steel 8

9 Micro Welding of tubes Material: 304 SS Speed: 3.5m/min (140 /min) Focal length: 100 mm Cover gas: Argon Laser Power: 90, 60, 30 W Tube diameter: 1.5 mm Wall thickness: 0.4 mm Bead on plate, fully penetrating Welding Brachytherapy seeds Welding Brachytherapy Seeds SPI Lasers 100W Fiber Laser Material Titanium Shield gas - Argon 35W power, 3s welding duration Tube length used for rounded end: ~1.2 mm 9

10 Welding guide wire components Material Stainless Steel Material thickness 2.2 mm Laser Power 60 W Cover gas Argon Focal length lens 100 mm Weld speed time 20 ms Thin sheet welding Material: Stainless Steel Thickness (both sheets): 25 mm Power: 30 W Spot diameter: 50 µm Weld time: 3 ms Weld method: Trepanning 200 μm 200 μm 10

11 Butt welding of fine wires Material: Tungsten Diameter: 75 μm Power: 20 W Spot size: 50 μm Pulse length: 1 ms Cover gas: Argon Butt welding of fine wires Material: Nitinol Diameter: 0.26 mm Power: 45 W Optics: 120 mm focusing lens, no beam expander Spot size: 60 μm Pulse length: 20 ms Cover gas: Argon 11

Wire Balling In medical applications numerous wires are used for

. No sharp edges can be tolerated Hitting the end of cut wire with laser

33mm diameter platinum wire melted SPI 70W Air Cooled laser Endoscope

12 Wire Balling In medical applications numerous wires are used for insertion.. No sharp edges can be tolerated Hitting the end of cut wire with laser gives round ball end with no sharp edges 0.33mm diameter platinum wire melted SPI 70W Air Cooled laser Endoscope welding Material: SS Power: 50 W Weld speed: 50 mm/sec Part Diameter: 1.4 mm Wall thickness: 0.1 mm Beam radius: 30 µm Courtesy of Fraunhofer Institute for Laser Technology 12

13 Rapid Prototyping x-y Scanner Laser Laser Beam Levelling System Window Metal Powder Part Part Laser Beam Powder Retractable Platform Courtesy of MCP-HEK Example Mainstream Application for Generative Microprocessing / Manufacturing Dental Caps! Images courtesy of MCP-HEK 13

14 Plastic Welding Plastic Welding of medical equipment Example: Catheter kit and syringe welding Fiber laser can give greater precision and finer spot size than DL Medical marking Diverse number of applications Data matrix Graduations Part numbers Marketing Wide range of materials Specific requirements Operating instruments need to go through sterilisation 14

Medical Aesthetics Wrinkle removal Compact laser module 1550nm

facility in Santa Clara to support customer applications Our

experience Customer samples are processed FOC on a case basis

undertaken on a commercial basis SPI offer a 30-day free

15 Medical Aesthetics Wrinkle removal Compact laser module 1550nm SPI s Application facility SPI has a dedicated technical facility in Santa Clara to support customer applications Our staff have over 50 years of combined laser materials processing experience Customer samples are processed FOC on a case basis for a proof of principle More detailed process development is undertaken on a commercial basis SPI offer a 30-day free evaluation laser Our on-site equipment includes commercially available systems 15

16 Summary Fiber lasers are an alternative source for many medical related device manufacturing applications Fiber lasers Low cost No maintenance Compact High quality Helping medical industry to: Reduce costs Improve quality Thank You Questions? 16

Joining dissimilar metals made possible with pulsed laser nano second welding

Joining dissimilar metals made possible with pulsed laser nano second welding March 2018 Marking Cutting Welding Micro Machining Additive Manufacturing Slide: 1 02/10/2017 CM-F00003 Rev 6 Micro joining