N O V E M B E R / D E C E M B E R 2 018 W W W. I N D U S T R I A L - L A S E R S .

C O M

VCSELs broaden
additive manufacturing
High-power blue laser
Marking inside glass
Industrial laser cleaning
Traceability in a factory
Servo control for laser
materials processing
India laser market grows

1811ILS_C1 1 11/6/18 8:22 AM

 Micromachining
Shouldn’t be a Giant Task

Linear Stages Integrated Servo/

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• Industry best accuracy and thermal
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 V O L 3 3 I N O . 6

NOVE MBE R /
D E C E M B E R 2 0 18

With up to 2.5 kW,

the working plane is
preheated independently
of the overall height of a

Features component. (Copyright:

Fraunhofer ILT, Aachen,
Germany/Volker Lannert)

P.
11

5
technology report

Project working towards blue

high-power diode laser
A new horizon for advanced laser
processing of copper SIMON BRIT TEN
VOLKER KR AUSE
13 application report
Ultrafast laser technology enables
internal engraving in glass
Process allows for improved traceability of
glass medical devices ROBERT BR AUNSCHWEIG
AND DAVID BRUNEEL
22 technology report
AND
Laser materials processing
drives new servo control
technologies
As laser materials processing
applications become more
challenging, digital servos must steer
laser beams with higher precision,
flexibility, and finesse than their
analog predecessors ERIC ULMER

25 technology report
16 technology report
Indian laser market
Laser cleaning is cost-effective
maintains growth trend
and reliable
Industrial Laser Solutions Editorial
Solution combines state-of-the-art cleaning
Advisor reports from India
with process monitoring and in-line process
ANANT DESHPANDE
control EDWIN BÜCHTER

19 technology report

Laser marking traceability

boosts a connected factory Departments
Technology meets increasingly complex 5 Update
supply chain needs DAVE SWEET
27 Calendar

27 Ad Index
W W W. I N D U S T R I A L- L A S E R S . C O M 28 My View

Market turbulence produces

DABbling
A blog by DAVID A . BELFORTE industry agita
David shares his insights and opinions on current
activities affecting industrial laser materials processing.
www.industrial-lasers.com/dabbling.html

1811ILS_1 1 11/6/18 8:22 AM

 Localized

Laser Manufacturing Facility in Brea, CA

AMADA’s global network

of manufacturing bases
includes facilities in North
America, Europe, China
and Japan.

1811ILS_2 2 11/6/18 8:22 AM

Manufacturing
AMADA is committed to the engineering
and manufacturing of the world’s most precise
and productive machine tools. Our most pop-
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The ENSIS Series is available in
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Laser cutting systems currently being man-
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Automation systems range from shuttle
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AMADA understands the distinct challeng-
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AMADA AMERICA, INC.

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www.amada.com/america
877-262-3287

1811ILS_3 3 11/6/18 8:22 AM

1811ILS_4 4 11/6/18 8:22 AM
 update
Additive manufacturing
process uses VCSELs to
heat parts from above
FRANKFURT AND AACHEN, GERMANY – Additive manufacturing pro-
cesses are booming, as evidenced by the rapid growth of the formnext
trade fair. At formnext 2018, in cooperation with the Chair for Technology
of Optical Systems (TOS) at RWTH Aachen University, the Fraunhofer
Institute for Laser Technology (Fraunhofer ILT) will be showing a new
process in which the component in the powder bed is heated with laser
diodes. The method results in
reduced distortion, generates FIGURE 1. With up to
taller parts, and enables use 2.5 kW, the working
of new materials. plane is preheated
At formnext 2018, a team independently
from Fraunhofer ILT and their of the overall
colleagues from RWTH TOS height. (Copyright:
will be presenting a new pro- Fraunhofer ILT,
cess. This process—laser Aachen, Germany/
powder-bed fusion (LPBF), Volker Lannert)
also known as laser beam
melting—can build parts with different patterns are pos-
less thermally induced stress sible. The process is mon-
and less distortion than con- itored with an IR camera.
ventional process technology. In another experiment,
The internal stresses are the engineers have con-
caused by temperature gra- structed parts in Inco-
dients in the generated com- FIGURE 2. Exposure at local preheating using a VCSEL is nel 718 and demonstrated
ponent. In the laser spot, shown. (Copyright: Fraunhofer ILT, Aachen, Germany/ significantly reduced dis-
temperatures above the Volker Lannert) tortion. The component
melting point prevail, while was heated up to 500°C.
the rest of the component cools rapidly. Depending on the geome- The VCSEL heating reduces the ther-
try and material, this temperature gradient can even lead to cracks mal gradient, thus also the stresses, making
in the material. To avoid this, the component is usually heated from it possible to produce taller parts. But even
below via the substrate plate. However, that isn’t enough, especially more interesting are the possibilities that arise
with taller structures. for particularly difficult materials—soon, com-
As part of the Digital Photonic Production (DPP) research campus, ponents made of titanium aluminides will be
a funding initiative of the German Federal Ministry of Education and produced. For this, the component will be
Research (BMBF), the experts from Fraunhofer ILT and the RWTH heated to approximately 900°C.
TOS Chair are working together with their partner Philips Photonics Such parts are commonly used, for
(Ulm, Germany) to develop solutions for this task. In the joint project example, in the hot gas section of turbo-
DPP Nano, they have developed a setup in which the component is chargers. In addition to turbomachinery,
heated from above (FIGURE 1). the process also opens up new prospects
For this purpose, an array of six vertical-cavity surface-emitting laser for other industrial sectors where thermally
(VCSEL) bars with 400 W each is installed in the process chamber. With induced stresses in additive manufacturing
infrared (IR) radiation at 808 nm, this array can heat the device from the processes have to be reduced.
top to several hundred degrees Celsius during the building process For more information, please visit www.
(FIGURE 2). The bars can be controlled individually so that sequences of ilt.fraunhofer.de.

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 5

1811ILS_5 5 11/6/18 8:22 AM

 update
IN MEMORIAM

Berthold Leibinger: A warm and gracious business leader

Many successful people had a mentor in
their career. I myself have mentored a num-
ber of individuals, and it’s a privilege for me
to be able to offer guidance and an honor
to be considered worthy to fill this role. I
also had mentors both early and late in my
career. One of them passed away recently
and I was saddened to hear this while I was
attending this year’s ICALEO in Orlando, FL,
a LIA event where in the past, he and I were
apt to meet.
Professor Berthold Leibinger, the for-
mer CEO and Chairman of the Supervisory
Board of Trumpf, passed away in Stuttgart,
Germany, on October 16, 2018, following
a long illness. Many obituaries and chron-
icles of the career of this outstanding gen-
tleman, who “dedicated his whole life to
his work as an entrepreneur and patron
of the arts,” will be published globally—so
rather than repeat his biography, I would
like to add an insight into what made up
his unique character.
I first met Dr. Leibinger when he was
expanding Trumpf in the U.S. in the 1980s.
It was at a Trumpf open house in the Farm-
ington, CT sales offices, where he took me
aside to ask questions regarding articles I
was then publishing about laser sheet metal
cutting and the annual market report I was
publishing in my magazine, Industrial Laser
Review (the predecessor to today’s Indus-
trial Laser Solutions).
In his fashion, he complemented my
editorial work, even referring to the earliest
paper on the subject that I had presented
at an FMA event in 1974. I was to learn this
was a Leibinger trait—a little praise, given in
a quiet, almost calm manner, to be followed
by a more stern comment on some matter
of his concern (this also gently delivered)
and then him gripping my arm with vary-
ing strength, depending on the intensity of
the admonishment. I can’t remember all the
issues we discussed, but I mainly recall the
way he delivered the message and how, be
it praise, criticism, or a rebuke, it was always
structured the same way.
We had many occasions to meet over
the years—at trade shows, conferences,
open houses, and company workshops,
where he always found time to talk with me.
The best times were at company-sponsored
events in Germany he invited me to attend,
where he allocated time for just the two of us
to talk about the growth of the laser market
and how ILS could be a factor in this growth.
He was a wise man and I always left these
meetings with fresh ideas on how I and ILS
could be more involved.
We developed a relationship that
exceeded business. He was very kind to
me and my wife Ginny, ensuring that on our
travels in Germany, we had opportunities to
see what he considered were places that
showed off a non-tourist view of the country.
Under his leadership, Trumpf grew to
one of Europe’s largest machine tool com-
panies and the world’s largest industrial
laser company. As his responsibilities at
Berthold Leibinger in 2010. (Courtesy:
Trumpf)
Trumpf expanded, we saw less of each
other—but on the occasions we did meet,
it never changed from the format of the first
meeting, a gracious greeting with some form
of praise, followed by an object message,
always couched in the gentlest of terms. I
can’t say this was his style with everyone,
but it was with me and I tried to emulate him
in my dealings with others.
It was only when I learned of his passing
that it occurred to me that Berthold Leibin-
ger had—intentionally or not—been a com-
petent, instructive mentor. And more than
that, a kind and generous gentleman. I shall
miss him and the world of industrial lasers
will miss his thoughtful analyses, his sharing
of Trumpf business news, and his leadership
in expanding laser cutting technology glob-
ally.—David A. Belforte

Partnership to create laser welding solutions

for electric vehicle battery enclosures
PITTSBURGH, PA AND ITASCA, IL – High-per-
formance polymers maker Covestro LLC
worked with Leister Technologies LLC (a
subsidiary of the Leister Group) to develop
process and material solutions for laser
welding fluid-cooled battery modules used
in electric vehicles such as new passenger
vehicles, electric buses, trucks, and other
utility vehicles.
“This joining technique provides the
accuracy needed for welding in tight loca-
tions and around other components in flu-
id-cooled systems,” says Fernando San-
tillana, senior project manager – Midwest,
East Coast, Caribbean, and Latin America Leister Technologies’ laser welding
at Leister Technologies LLC. process can be used to join and seal
Laser welding is traditionally only used fluid-cooled battery enclosures made of
with translucent or optically clear plastics. Bayblend FR3010 PC+ABS blend.

6 Industrial Laser Solutions NOVEMBER/DECEMBER 2018 www.industrial-lasers.com

1811ILS_6 6 11/6/18 8:22 AM


Now, the two companies have extended use
of this joining technique to include opaque
flame-retardant Bayblend PC+ABS blend
from Covestro, while achieving the same
level of weld strength (FIGURE). Flame-re-
tardant plastics are preferred and often
required for battery enclosures, as they
can help prevent or delay the spread of fires.
Bayblend FR3010 PC+ABS blend fea-
tures high-impact strength, chemical and
hydrolysis resistance, thermal stability, and
a balance of high-heat distortion and phys-
ical performance.
“Using Bayblend FR3010 PC+ABS blend,
we developed effective and reliable laser
welding solutions for production-ready
battery modules that can withstand bat-
tery abuse testing, including UN38.3,” says
Terry Davis, principal engineer at Covestro
LLC. “With this material, battery manufac-
turers can create reliable and leak-free bat-
tery enclosures.”
For more information, please visit www.
covestro.us and www.plastics.covestro.com.
PERMANENT, HIGHLY DETAILED MARKING &
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RS SHIP SAME DAY WHEN PLACED BY 4 PM LOCAL TIME
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1811ILS_7 7
Ultrashort-pulse lasers produce micropatterns
on engines to reduce fuel consumption
DRESDEN, GERMANY – Engineers at the
Fraunhofer Institute Institute for Material
and Beam Technology (Fraunhofer IWS)
are using ultrashort-pulse lasers to gener-
ate very fine and friction-reducing fishbone
patterns in engines, with the goal of reduc-
ing the fuel consumption of cars by more
than a tenth (FIGURE).
Udo Klotzbach, an electrical engineer
at Fraunhofer IWS involved in the work,
estimates that if selected individual parts
in combustion engines were treated with
this process, cars could save several-per-
cent gasoline or diesel. “If we also use it
to machine plain bearings, rolling bearings,
and other moving vehicle parts and cal-
culate this for the entire car, we can even
achieve savings in the double-digit per-
centage range,” he says. What’s more, he
adds, the components last about 30% lon-
ger on average.
NOVEMBER/DECEMBER 2018 Industrial Laser Solutions
update
When the pistons in a car engine move
up and down several thousand times a min-
ute, they rub against the inner wall of the cyl-
inder. This friction slows them down, wastes
kinetic energy, and ultimately also fuel. In
addition, small material losses and defor-
mations damage the engine over time—up
to the notorious “piston seizure.”
Similar friction problems arise in many
machines—for example, in locomotives
and milling machines. Even modern elec-
tric cars waste part of their battery charge
through friction in the electric motor and
other moving parts. Forecasts indicate that
friction and the associated wear consume
2–7% of Germany’s annual economic out-
put. Although friction cannot be completely
avoided, however, it can be reduced. As an
example, the engineering team has tested
its anti-friction technologies on piston rings,
which enclose the engine pistons like a seal
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 update
to keep lubricating oil away from the com-
bustion chamber.
Using lasers that emit very short, but
high-energy light pulses, the engineers
could generate a few micrometers of small
holes on the piston rings. As a result, pat-
terns are created that are barely percepti-
ble to the naked eye, but look like drainage
channels or fishbones under the microscope.
These bone patterns have two functions:
“On the one hand, they reduce the areas
that can rub against the cylinder wall at all,”
Klotzbach explains. “On the other hand, the
channels direct the engine oil to the areas
where the greatest frictional losses normally
occur. In a sense, if we stick to the fishbone,
its spine is the channel through which new
oil flows when needed.” This causes a pro-
tective oil film to float between the ring and
the inner wall of the cylinder at all times when
the engine is running.
Ultrashort laser pulses generate
micropatterns in engine parts such as
piston rings and thus reduce friction; the
Fraunhofer IWS technology is designed
to reduce wear and friction and save fuel.
(Copyright: Shutterstock/Fraunhofer IWS
Dresden)
However, the laser must generate the
bone pattern with high precision without
producing sharp burrs. This is why the engi-
neers are also employing ultrashort-pulse
lasers, which emit light pulses that often
only last 500 fs. In comparison, two trillion
of these pulses are needed until a whole
second has passed. “Because these pulses
are so short, the material hardly heats up,”
Klotzbach explains. “There are virtually no
undesired effects on the material.”
In the meantime, the engineers have also
developed laser speeds that allow the tech-
nology to be used in mass production. They
are now testing this process together with
partners from the automotive industry. They
are also exploring other applications for their
micropatterns—for example, in mechanical
engineering and for sports equipment.
For more information, please visit www.
iws.fraunhofer.de.

Fiber laser maker SPI Lasers purchases

Rugby manufacturing site
RUGBY AND SOUTHAMPTON, ENGLAND – company’s vertical integration programs ton headquarters and increased presence
Fiber laser designer and maker SPI Lasers, and further optimize their manufacturing in China and the U.S.
a wholly owned subsidiary of Trumpf and production processes. For more information, please visit www.
(Ditzingen, Germany), has purchased an This announcement follows in the wake spilasers.com.
8.1-acre manufacturing site in Rugby, in of the company’s growth at its Southamp-
a deal worth £10.3 million (over
$13.1 million). This purchase
will see the company expand
its manufacturing footprint in
Rugby by approximately 100%,
bringing its total usable space
up to approximately 80,000 sq.
ft (FIGURE).
“The facility allows us to focus
not just on enhanced manufac-
turing capabilities, but also R&D—
ensuring our products remain at
the forefront of fiber laser tech-
nology,” according to SPI Lasers’
CEO Mark Greenwood.
Over the coming months, the
newly acquired site will be the
subject of a multi-million-pound
refurbishment with the express
intention of utilizing the addi-
tional space to accelerate the SPI Lasers’ manufacturing site in Rugby.

8 Industrial Laser Solutions NOVEMBER/DECEMBER 2018 www.industrial-lasers.com

1811ILS_8 8 11/6/18 8:22 AM

 update
Laser cutting produces components
for steam-powered rocket bike
MALTON, ENGLAND – Full-service sheet metalwork manufacturer

Malton Laser has provided a series of stainless steel components

for the Force of Nature steam-powered rocket bike created by
motorsport and drag racing enthusiast Graham Sykes (FIGURE).
Five years in the making and built entirely in the UK, Sykes
has developed Force of Nature in a bid to break both the world
steam-powered vehicle record and world thrust motorcycle record.
As a fellow motor racing enthusiast, Charles Corner, managing direc-
tor at Malton Laser, was keen to be involved with the project and man-
ufactured stainless steel components for the bike’s charging dock.
The charging dock is where the Force of Nature bike will spend Graham Sykes (left) and Charles Corner (right) with the Force of
most of its time and will feature an automatic docking system, which Nature.
will primarily be used to raise and lower the bike off the ground.
Malton Laser’s engineers used laser cutting to cut a series of stain- cation services to manufacture components for such an important
less steel parts for the docking system with the Bystronic ByStar part of Force of Nature is something we’re really excited about,”
Fiber 3015 6 kW laser system. Corner says.
In addition to the laser-cut parts, Malton Laser has implemented The name Force of Nature was chosen for the bike to reflect its
its fabrication and welding expertise to manufacture a number of the green credentials. It will be powered using natural resources, namely
components that will form Force of Nature’s charging dock. water and biofuel made from vegetable oil.
“The charging dock is integral to the efficient running of the For more information, please visit www.maltonlaser.com and
bike, so to be able to utilize our laser cutting, welding, and fabri- www.sykoracing.com.

No compromises.
The first fiber laser to provide high quality thick metal cutting and high
productivity thin metal cutting with none of the cost and complexity of
free space optics. Helping to grow your business without compromise.

www.nlight.net

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 9

1811ILS_9 9 11/6/18 8:22 AM

1811ILS_10 10 11/6/18 8:22 AM
 t e c h n o l o g y
Project working towards
blue high-power
diode laser
A NEW HORIZON FOR ADVANCED LASER PROCESSING OF COPPER
SIMON BRITTEN AND VOLKER KRAUSE
A
s part of the German govern-
ment-funded project EffiLas,
Laserline is developing the first
high-power blue diode laser
sources based on laser bars. In
cooperation with laser bar man-
ufacturer Osram, the established
power scaling technology for the near-infrared (near-IR) wave-
length is applied for the first time for the blue wavelength. This
article reviews the motivation, the technology, and the first
applications with a high-power blue diode laser having up to
700 W power.
50 W
Over the last few decades, continu-
ous-wave (CW) powered laser appli-
cations have become established as a
versatile tool in modern manufacturing
operations, covering welding, cladding,
surface treatment, hardening, brazing,
cutting, and more. The shift from a sci-
entific technology to a common pro-
duction tool has been pushed by the FIGURE 1. The
ongoing research of new laser sources, concept of power
which have continuously enabled new scaling with
applications. diode bars for the
The first developments in high-power high-power blue
CW laser technology occurred before the diode laser is
millennium—the establishment of car- shown.
bon-dioxide (CO2) lasers at 10.6 µm and
diode-pumped Nd:YAG lasers at 1064 nm. CO2 lasers, how-
ever, could not be fiber-delivered and Nd:YAG systems were
limited in brightness and power-scaling capability. After the
millennium, the fiber laser started to emerge as a solution for
high-brightness lasers that could be fiber-delivered and now-
adays are a substitute for CO2 lasers in many applications.
www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions
1811ILS_11 11
r e p o r t
High-reflectivity material challenges
These CW lasers are primarily working in the ~1 µm range. For
example, this wavelength is suitable for processing of steel,
with over 50% absorption, but is very challenging for materi-
als such as copper, which has an absorption of <5% at 1 µm.
To process these high-reflectivity materials, high laser inten-
sity is used to create a vapor channel in the material, which
increases the absorption. However, this approach limits cop-
per processing to a deep penetration process regime, with the
inherent risk of sputter occurrence and challenging control of
energy deposition.
500 W
A wavelength below 500 nm is much more suitable for pro-
cessing of copper, as the absorption increases strongly to
over 50%. Some solid-state laser sources are available on the
market in this wavelength range that are based on frequen-
cy-doubling, resulting in wavelengths of 515 and 532 nm (green
spectrum). However, these laser sources rely on a process in
which a crystal is converting only a fraction of the pumped
laser wavelength into the target wavelength. The conversion
process leads to high power losses, complex cooling require-
ments, and a sophisticated optical setup.
The solution to this technical challenge is addressed
with additional urgency because of the close connection to
the social challenge of reduction of greenhouse gas. The
11
11/6/18 8:22 AM
 t e c h n o l o g y r e p o r t

replacement of combustion engines with electric engines creates a) b)

a vast demand for reliable processing solutions for copper, which
is used in eMobility as well as in other renewable energy systems
such as wind turbines.

Goals to increase processing efficiency

To address this challenge, Laserline, together with Osram and
other partners, started the BlauLas project in 2016, with the goal
of developing the first high-power diode laser with a blue wave- FIGURE 3. Cross-section of a joint between 34 stacked copper
length of 450 nm.1 In contrast to other laser source concepts, the foils (each 11 µm) in butt welding (a) and edge welding
diode laser based on gallium nitride material enables the direct configuration (b), welded with a laser power of 580 W and 2 m/
emission of 450 nm, without further frequency-doubling and there- min feeding velocity.
fore with higher energy efficiency. With a wavelength of 450 nm, an
increase of processing blue laser bars on heat sinks. In contrast to other blue laser con-
efficiency by a factor cepts that rely on single emitters with <5 W output power, a single
of 20X is expected for diode bar is already creating a power level of up to 50 W. Using spe-
copper material com- cial optics, it is possible to combine several mounted diode bars in
pared to a wavelength a stack and even combine two stacks in one laser source (FIGURE 1).
around 1 µm. The success of this approach has been demonstrated with the
Based on long-term presentation of a 700 W high-power diode laser with a beam qual-
proven scaling tech- ity of approximately 60 mm*mrad.2 The laser beam delivery to the
niques, Laserline uses workpiece is achieved with a 600 µm fiber and a conventional focus-
laser bars from Osram ing optic, which is equipped with an adjusted antireflection coating
FIGURE 2. Welding of a copper sheet to mount, electrically to the blue wavelength. The actual ongoing project has set the goal
with 450 nm wavelength is shown. connect, and cool the to develop a blue high-power diode laser with over 1000 W of CW
power, opening up new applications beyond copper processing.
With the application of 450 nm, melting of copper material in the
heat conduction mode is possible, allowing precise adjustment of
the melt pool geometry for thin copper materials (FIGURE 2). The
stable energy deposition and heat conduction process regime is
especially important for applications in which the high pressure of
a keyhole welding mode would lead to a cutting of the material or
an undesirable spatter occurrence. This can occur while welding

HIGH POWER stacked thin copper foils, which may be subject to an uncontrolled
gap because of warping of the stacked foils (FIGURE 3).
BLUE LASERS While applying a butt welding approach with 580 W laser power
and 2 m/min feeding speed on stacked copper foils, a weld bead
width of more than 0.8 mm can be created with minimal poros-
ity and low undercut. For a fillet weld approach with an irradia-
tion on the edge of the foil stack, the foil endings are melted into
a high cross-section area with a complete attachment to the solid
foils. In both butt and edge welding, the process results in a per-
fect mechanical joint as well as very good electrical conductivity.
With an outlook to more than 1 kW blue laser power and a poten-
tial to achieve a power increase together with an improvement of
the beam quality, Laserline is convinced that diode lasers are going
to be the leading photonic tools in medium- to high-power mate-
Spatter-Free™ Cu Welding rial processing soon. ✺

Conduction & Keyhole Mode REFERENCES

1. See https://goo.gl/KVJFnn.
2. A. Balck et al., “700 W blue fiber-coupled diode-laser emitting at 450 nm,” Proc. SPIE, 10514,
1051403 (Feb. 19, 2018).

WWW.NUBURU.NET
SIMON BRITTEN (simon.britten@laserline.com) is in innovation management/new
business development and VOLKER KRAUSE is a founder and managing director,
both at Laserline, Mülheim-Karlich, Germany; www.laserline.com.

12 Industrial Laser Solutions NOVEMBER/DECEMBER 2018 www.industrial-lasers.com

1811ILS_12 12 11/6/18 8:22 AM

 a p p l i c a t i o n r e p o r t

Ultrafast laser
technology
enables internal
engraving in glass
PROCESS ALLOWS FOR IMPROVED

TRACEABILITY OF GLASS MEDICAL DEVICES

ROBERT BRAUNSCHWEIG AND DAVID BRUNEEL

F
emtosecond laser technology applied and induced stress in and around the laser-affected zones.
in glass is used in various fields. For These effects depend on laser parameters such as pulse
example, marking in glass allows the energy and energy deposition. For instance, energy deposi-
traceability of syringes or other devices tion Ed is calculated according to the scan speed, the pulse
made of glass, which represents a huge energy, the repetition rate, and the spot size at the focus point
market in the pharmaceutical and med- as summarized below:
ical fields.
4Epf
Recognizing this, femtosecond laser machine maker Lasea Ed =
πWv
and its partners have developed a non-aggressive internal
engraving laser system (NAGINELS) process to mark diffrac- where Ep is the pulse energy, f is the repetition rate, W is the
tive data matrices inside glass-based syringes without cracks spot diameter, and v is the scanner speed.3
and that can be read by an external instrument.1,2 Patented in FIGURE 1 illustrates these effects on glass while increasing
2008, the technology can also be applied to different types the energy deposition. The pattern consists of a square area
of glasses. This article describes the process principle and filled with parallel lines inscribed in glass and spaced by a few
the validation process in terms tens of micrometers to obtain
of reading and quality con- a diffractive effect.
trol, and provides associated Colored At low energy deposition,
industrial solutions. centers NAGINELS Micro-cracks colored centers form and
are not permanent. Indeed,
Physical principle after a few weeks or by heat-
When a femtosecond laser ing the structures, these col-
interacts with glass, structural ored areas disappear. This
modifications and a volume Increasing of the energy deposition is because of the depos-
variation occur at the focus ited energy being not suffi-
point, leading to colored cen- FIGURE 1. Effects at the focus point after femtosecond laser cient enough to break atomic
ters, refractive index variation, irradiation are shown. bonds and, after a certain

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 13

1811ILS_13 13 11/6/18 8:22 AM

 a p p l i c a t i o n
time or with the help of the heat, the material returns to its original
state. When the energy deposition increases, permanent struc-
tures form and volume variation creates a refractive index varia-
tion. Managing these variations, we create diffractive structures.
a) b)
c)
d)
FIGURE 2. Elements used for the process include the Satsuma
air-cooled femtosecond laser from Amplitude Systèmes (a), the
LS-Shape special beam shaper from Lasea (b), the LS-Scan high
dynamic scanner from Lasea (c), and turn wheel for handling and
control from Lasea (d).
14 Industrial Laser Solutions NOVEMBER/DECEMBER 2018
1811ILS_14 14
r e p o r t
At higher energy, micro-cracks start to form and propagate,
which can lead to breaking the entire piece of glass.
From these results, laser parameters can be defined to engrave
diffractive gratings and prevent crack formation. Data matrices
have a square shape made of cells to stock information. The num-
ber of cells is chosen according to the quantity of information
that we want to write. Each cell is made of a grating. The diffrac-
tive effect needs to have a sufficient contrast for the marks to be
read and decoded.
Systems used for the process
An air-cooled femtosecond laser emitting in the infrared (IR) is
focused in glass by a special lens mounted on the scanner head to
mark the lines. A beam shaping system is used to adapt the beam
before the scanner head, allowing adjustment of the spot size. The
scanner head moves the beam in the sample at a very high speed.
FIGURE 2 shows the typical writing setup.
After defining the laser parameters for a new type of glass, val-
idations on thousands of syringes must be done to check for the
lack of micro-cracks. To do so, we take pictures with a 10X confocal
microscope. FIGURE 3 illustrates an example of a data matrix image.
A range of energy deposited is tested and a security margin
is defined. Additional tests (for example, crush and vision tests)
are then done by Lasea’s customers to verify the syringe integ-
rity impact.
Data matrices made of gratings are illuminated with a lamp under
a given angle, so that the light is diffracted when passing through
the gratings. A camera takes a picture of the illuminated data matrix
and a software or application decodes the information. FIGURE 4
shows an example of illuminated data matrices with white light
and blue LEDs.
An automated system combining those elements can be inte-
grated in a machine with different sources and cameras. The light-
ing and camera are then optimized to get a Grade 4 on all high-
speed readings (up to 600 syringes/min).
Industrialization
The laser parameters and scanner parameters are set using Kyla,
Lasea’s micromachining software. Any machine can integrate
these elements,
adapted accord-
ing to the applica-
tion. For instance,
we have developed
machines com-
bining a wheel on
which syringes are
fixed and synchro-
nized with the scan-
ner mirror’s move-
ments (FIGURE 5). The
wheel turns in front
200 µm
of the scanner and a
trigger allows mark-
FIGURE 3. An example of a grating ing on-the-fly as
inscribed in a syringe is shown. each syringe passes
www.industrial-lasers.com
11/6/18 8:22 AM
 a p p l i c a t i o n
a)
Syringe
Lamp
Camera
b)
600 µm 600 µm
Data matrix Data matrix
in a glass plate in a glass syringe
FIGURE 4. The decoding system (a) and
examples of illuminated data matrices (b)
are shown.
through the scanner field. Nesting and
denesting systems can be added before
and after the marking process.
FIGURE 6 shows an example of a marked
syringe—a data matrix is written in the
syringe and illuminated with white light.
Conclusion
Lasea and its partners have developed a
process to mark syringes or other glass-
based devices for traceability. This pro-
cess can also be used for decoration
since diffractive structures are printed.
Laser parameters can be controlled for
a)
b)
FIGURE 5. The NAGINELS marking system
(a) and denesting system (b) are shown.
www.industrial-lasers.com
1811ILS_15 15
r e p o r t
Paul-Etienne Martin,
general manager
of Lasea France
(Pessac, France);
Eric Mottay, CEO of
Amplitude Systèmes
(Pessac, France);
FIGURE 6. An example of a marked syringe is shown. and Teddy Klein,
global engineering
the diffractive effect and avoid crack for- – technology program leader at Sanofi-
mation, which is very important in the Pasteur (Lyon, France), for their contribu-
pharmaceutical industry. Indeed, liquid tions to this article.
inside a syringe will be injected into the
REFERENCES
human body, so particles of glass are
1. J. Remits, “Des gravures invisibles et anti-contrefaçon,”
unacceptable. Most importantly, this pro- Trends-Tendances, 84 (Jan. 10, 2008).
cess is currently being industrialized and 2. Project supported by the European Commission “Naginels”
implemented with Lasea’s capabilities at (COOP 512931) with the following partners: Lasea,
Amplitude Systèmes, Costet, TBS, and ALPhANOV.
Sanofi-Pasteur, a major pharmaceutical 3. S. Rajesh and Y. Bellouard, Opt. Express, 18, 20, 21490–
company. ✺ 21497 (2010); doi:10.1364/oe.18.021490.
ACKNOWLEDGEMENTS ROBERT BRAUNSCHWEIG (rbraunschweig@lasea.
com) is general manager and vice president of U.S.
The author would like to thank Axel
sales for Lasea Inc., El Cajon, CA; www.lasea.com,
Kupisiewicz, CEO and founder, and while DAVID BRUNEEL is processing and model-
Audrey Champion, project engineer – R&D, ing unit manager of the R&D department at LASEA SA,
both from Lasea SA (Angleur, Belgium); Angleur, Belgium.
Fiber Lasers for Materials Processing
Green picosecond 1 µm picosecond
15, 30 W 30, 60, 100 W
Green nanosecond 1.55 & 2 µm, ns
10, 20, 30, 50 W 1.55 μm: 5 ns, 50 μJ, 5 W
2 μm: 5/30/200 ns, 50-500 μJ
Highest Peak Power Fiber Lasers, All-Fiber Structure, Reliable, M2 < 1.2
www.advaluephotonics.com • +1-520-790-5468 • Tucson, Arizona, USA
NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 15
11/6/18 8:22 AM
 t e c h n o l o g y
Laser cleaning is cost-effec
SOLUTION COMBINES STATE-OF-THE-ART CLEANING WITH
PROCESS MONITORING AND IN-LINE PROCESS CONTROL
EDWIN BÜCHTER
L
aser cleaning started in Germany in
the late 1990s and the technology has
since established itself in industry. For
example, in the U.S., several hundreds
of installations in automotive, aeronau-
tics, and general industry have proven
the potential of laser cleaning.
The laser-based surface pretreatment of industrial compo-
nents and surfaces is often an economical alternative to con-
ventional component cleaning. In addition to its low energy
consumption, the media-free process does not require any
chemicals or abrasives, which is why cleaning with light is par-
ticularly sustainable and environmentally friendly.
To avoid damaging the surface of the component, industrial
cleaning lasers with short pulses are used. Depending on the
intensity, pulse duration, and wavelength, different effects and
surface properties can be adjusted. The spectrum ranges from
gentle cleaning to selective surface structuring. The effect of
laser radiation depends on the absorption of the processed
material (FIGURE 1).
Metals have a high reflectivity for the typical solid-state
wavelength of 1064 nm, while impurities and oxides on the
surface will absorb the laser radiation better. Moderate beam
266 nm
355 nm
100 532 nm 1064 nm
75 Silver
Absorption
(%) 50
Copper
25
Aluminum
0 various industrial applications, including pretreatment of joints
400 600 800 1000 1200 1400
Wavelength (nm)
FIGURE 1. The absorption spectrum of different metals is
shown. (Courtesy: Laser Zentrum Hannover [LZH])
16 Industrial Laser Solutions NOVEMBER/DECEMBER 2018
1811ILS_16 16
r e p o r t
intensities can therefore
be used to remove con-
tamination from the sur-
face without damaging FIGURE 2. Precise decoating
the metal underneath. of metallic surfaces is
When cleaning with light, demonstrated.
organic and acidic oxide
contaminations are effi-
ciently blown off from
the surface of metallic
components.
By intensifying the
laser parameters, metal-
lic materials in the upper-
most boundary layer (typ-
ically up to 5 µm) can be
modified to create struc-
tures or roughness. One
example is to improve FIGURE 3. The Share Motion
the corrosion behav- special optics for the machining
ior of light metals and to of slot spring geometry are
increase the surface area shown.
by roughening.
Laser beam cleaning offers high precision and reproducibil-
ity, therefore saving enormous costs in industrial series produc-
tion. The investment in current laser technology is often many
times cheaper than that in, for example, wet chemical alter-
natives. In addition, the running costs of highly efficient laser
machines are usually significantly lower because of their low
energy consumption (a few kilowatt hours) and moderate main-
tenance requirements. Significant savings in component unit
costs can thus be achieved, especially with large part quanti-
ties and fully automatic processes.
The flexibility that laser cleaning offers makes it suitable for
for bonding and welding; accurate contour removal of coating
to, for example, provide electrical contact; paint stripping for
adhesive pretreatment; and post-treatment of welding seams
and descaling of steels prior to varnishing/cathodic dip coat-
ing (FIGURE 2).
www.industrial-lasers.com
11/6/18 8:22 AM
ective and reliable
Standard optics and special versions formed, which are mainly found
Laser beam cleaning optics are available for a wide range of as islands. These lie on the rel-
applications. Optics are connected to the powerful base units atively smooth surface and can
by means of fiber-optic cables, have an application-oriented be removed very well with the
design, and have been developed, in part, for complex compo- laser. In the edge area of the
nent geometries. weld seam (the seam root), the FIGURE 5. Residue-free laser
For example, the optics of the Share Motion series can clean a silicates can be partially well- after-treatment of weld
vertical tongue-and-groove geometry (FIGURE 3). The optics only bonded and shaded by the seams.
need to be moved along the groove by means of a linear move- throw-up, and can therefore be
ment. Because of the multiple beam deflection, it is possible to removed more difficultly. The
achieve an efficient adhesive pre-treatment with a simple move- laser beam is directed to the
ment and almost no nonproductive times at an optimum beam surface at an incidence angle
angle. Depending on the complexity of the path contour, the effi- <90° to remove these edge silicates. In this way, these areas
ciency increase in process quality and speed that can be achieved can also be removed without leaving residues, even at high laser
compared to conventional robot-guided motion is up to 76%. intensity (FIGURE 5). By means of an additional after-cleaning with
the laser, tarnishing colors that occur at high intensities can be
Post-weld cleaning removed again.
CleanLASER offers laser-safe cleaning machines that can be inte- The laser process replaces cost-intensive and nonreproducible
grated directly into running production because of their modular brushing and blasting processes, especially for aluminum and steel
and compact design, which can be adapted to individual customer welds. The processing speed is up to 10 m/min.
requirements in terms of laser power, workspace, and loading.
The mobile lightCASE compact laser system has uses, for exam- Process monitoring
ple, in nondestructive testing and weld seam stripping in aviation The interaction of the laser beam with the surface not only leads
or shipbuilding. to a modification of the surface, but also to characteristic process
The lightCASE system’s steel housing with carrying handle is lights during processing. During the evaporation of the soiling
as compact as a beverage crate. Its 100 W laser is operated via and the metal oxide layer close to the surface, a plasma is gen-
an intuitive touchpad panel. The system has already proven its erated that, depending on the radiation intensity, shines brightly
worth in very cramped operat- for simple detection, therefore enabling effective process control.
ing conditions—for example, in Plasma intensity measurement is a special method that can
the case of partial weld seam only be used in the laser process and combines numerous dis-
stripping for nondestructive turbance variables in a collective signal. Clean-Lasersysteme
testing in the interior of a sub- (Herzogenrath, Germany) has developed a plasma sensor that
marine (FIGURE 4). records the brightness curve during laser processing and com-
Welding seams can be spe- pares the measured curve with reference curves or fixed limit val-
cifically re-treated and the sur- ues to determine a measure of process capability. Flexibly con-
faces removed from depos- figurable, graphically based software supports the setup of the
its. The laser cleaning process, system with automatic measurement and reference functions.
which is carried out at short Therefore, minimal intensity fluctuations can be detected in the
intervals directly after the weld- production process and limits for quality characterization, and
ing process, enables dirt, oxide, 100% in-line control can be defined and used according to dif-
silicate, and slag layers to be ferent criteria. The component itself neither needs to be touched
removed quickly and cost-effec- nor removed from the process for the measurement.
tively. After the melt has solid- The final goal for all the company’s laser systems is to minimize
ified, oxides and silicates are costs and reduce the burden on the environment. ✺
FIGURE 4. The lightCASE removed from the surface with
compact cleaning lasers the CleanLASER. EDWIN BÜCHTER (edwin.buechter@cleanlaser.de) is managing part-
have utility in aviation and In the middle of the weld ner of Clean-Lasersysteme (cleanLASER), Herzogenrath, Germany;
shipbuilding. seam, a large area of silicates is www.cleanlaser.de.

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 17

1811ILS_17 17 11/6/18 8:23 AM

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1811ILS_18 18 11/6/18 8:23 AM

 t e c h n o l o g y r e p o r t

Laser marking
traceability boosts
a connected factory
TECHNOLOGY MEETS INCREASINGLY

COMPLEX SUPPLY CHAIN NEEDS

DAVE SWEET

W
hen I came home from Whether you call it the IIoT, smart manufacturing, The
work the other night, a Connected Factory, or Industry 4.0, this convergence of infor-
light came on. Literally, I mation and operations technology spells a new era in how we
used a smartphone app work and how we do business. When we connect the plant
to activate my smart floor to high-level software, we are multiplying the value of
wall switch, which is our manufacturing operations. This is because we are gain-
connected to a wireless ing prime insights from collected data that power strategic
network. This useful gadget is part of the Internet of Things management decisions and steer companies toward their
(IoT), just like many of our home devices, from watches to refrig- larger goals.
erators—all designed to make our daily lives easier. And even
with all these advances, there is still a much broader potential A new era
in our connected world. As expected, with change comes new challenges as well. In the
When we shift that conversation from consumer-based IoT to connected world, technologies are constantly evolving and sup-
the Industrial Internet of Things (IIoT), we open the door for new ply chains are becoming increasingly complex. As consumers
opportunities to not just make our lives easier within our homes, and manufacturers demand greater transparency, many indus-
but to make our world safer, more efficient, and more productive. tries are finding themselves under more intense scrutiny from
various regulatory bodies. Sectors such as auto-
motive, pharmaceutical, and electronics are facing
the costly threat of product recalls.
Another issue that has grown in recent years is
counterfeit goods. Since 2010, the MSRP value
of falsified parts and products has grown by over
500%, according to U.S. Customs and Border
Protection.
Component- Subassembly Major Final assembly Complete What we need right now is better traceabil-
level ID ID assembly ID ID component
traceability ity. Luckily, the process of identifying, verifying,
and tracing parts throughout their lifetime has
grown even more sophisticated as technology
FIGURE 1. Unique identifiers are eternally tied to the part and stored in a advances bridge the gap between the physical
secure database, allowing for complete product traceability. and digital worlds.

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 19

1811ILS_19 19 11/6/18 8:23 AM

 a p p l i c a t i o n
Traceability begins when we use laser
marking equipment to directly mark parts
with unique identifiers or other informa-
tion. The connected factory enables that
information to be collected and stored in a
secure database, so parts can be tracked
throughout the manufacturing process.
From point A to point Z, intelligent soft-
Fiber Laser
Gain Fiber
Yb 14/250
Cladding Pumped
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& High Efficiency
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FIGURE 2. Automated mark grading and verification ensure durability and prevent
duplication.
visit us at
www.ofsoptics.com ware records a complete history of the
part’s activities, creating a genealogy rel-
ative to the main part number and subas-
semblies (FIGURE 1).
In essence, traceability is making our
world safer, more efficient, and more pro-
ductive, one part at a time.
Connect, mark, trace
More manufacturers are implementing
IIoT-enabled track and trace technology
to ultimately gain greater control over their
operations. In fact, in 2017 more than 50%
of industrial professionals had either
invested in IIoT technology or planned to
do so, according to LNS Research (www.
lnsresearch.com). Traceability within the
connected factory allows industries to
drive efficiency gains in the form of faster
access to data, allowing you to stay ahead
of industry regulations and technology
changes, while continually improving
operational efficiencies. Here are five of
20 Industrial Laser Solutions NOVEMBER/DECEMBER 2018
1811ILS_REV_20 20
r e p o r t
the benefits you can realize with a con-
nected traceability system.
Improved efficiency through automation.
Effective part traceability cannot happen
in a vacuum. It requires coordinated com-
munication of complex systems to prevent
production bottlenecks, waste, and other
costly errors.
A connected factory means that every-
thing is integrated to work together for
higher performance and efficiency. This
hands-off approach opens the door for
automated assembly lines and, when inte-
gration is done properly, your data qual-
ity improves.
By natively integrating laser marking via a
communication protocol such as Ethernet/
IP, the result is a faster setup that does not
require custom interface software. Data is
transferred seamlessly, and information is
communicated immediately to all devices.
Many laser marking traceability sys-
tems can be configured to meet your spe-
cific needs based on your materials, pro-
cesses, plant layout, and other factors. So
even if you are still using the paper-and-
pen method, there are entry-level traceabil-
ity systems available for you to get started,
while enabling you to scale up in the future.
Enhanced quality control. An auto-
mated smart factory is equipped with the
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11/29/18 11:57 AM
 a p p l i c a t i o n
necessary controls to improve your mark
quality, accuracy, and ultimately traceabil-
ity (FIGURE 2).
Successful integration results in:
· Preventing serial number duplication by
enforcing text field uniqueness
· Auto-verifying, thanks to integrated
vision interface modules that grade
marks
· Auto-sorting of “pass” and “fail” parts
· Auto-remarking if a mark fails verification
· Enhancing overall quality
· Minimizing faulty part distribution
· Saving costs long-term
Informed decision-making with real-time
manufacturing data. Because information
is communicated automatically within the
connected factory, you are seeing data in
real time. This provides a goldmine of infor-
mation that can help manufacturing oper-
ations’ management to see, analyze, and
quickly act upon time-sensitive data com-
ing off the shop floor.
As you are able to collect more infor-
mation-rich data on inventory and other
key performance indicators, you can
make more informed decisions on how
to improve your performance. Although
good intuition cannot be discounted, data-
driven decision-making gives you the fac-
tual, quantitative insights to answer vital
business questions and acquire any stake-
holder support.
Protection against counterfeiting.
Counterfeit and diverted goods are an
expensive problem for manufacturing
companies. In fact, each year as much
as $500 billion of U.S. trade is lost to
counterfeiting, according to the World
Customs Organization (www.wcoomd.org).
Reproduced, returned, or resold products
not only diminish your brand equity, they
can also directly impact your bottom line
in the form of liability, warranty fraud, and
other expenses.
Having an IIoT-based traceability sys-
tem in place means that you are better
protected from these risks. Laser mark-
ing equipment is capable of creating per-
manent, verifiable marks to help manufac-
turers recognize and isolate fraudulent vs.
authentic parts, thus reducing liability.
In the connected factory, the solution is
a 2D data matrix or other laser-marked bar-
code that can be used to link the product
back to the rest of your production data.
www.industrial-lasers.com
1811ILS_21 21
r e p o r t
For more advanced applications, a unique,
covert identifier can be marked on the part
to add an extra layer of security for coun-
terfeit protection.
Prevent or reduce the impact of a recall.
Product recalls can happen at any time.
How your company responds is critical,
and a connected traceability system helps
manufacturers react quickly and effectively.
At the moment your company or a third
part initiates a recall, affected products
can be traced back directly to the origi-
nal source. Recorded part data minimizes
uncertainty during a recall and helps to
reduce its scope.
In the end, your immediate action and
transparency help to maintain customer
and supplier confidence. And since the
recall was contained, associated costs are
kept at a minimum.
Tying everything together
Many companies understand these ben-
efits but may struggle with how to get
started. While the opportunities of the
connected factory are exciting, initiating a
connected track and trace system in your
operation requires many management con-
siderations. Three important factors to
consider in your cost-benefit analysis are:
1. How much do you currently spend on
wasted or scrapped material?
2. What amount do you invest in recall
remediation?
3. Does your company face counterfeit-
ing or gray market risks and liability
expenses?
As said, successful traceability within the
connected factory requires a complex
web of communication. Yet, understand
that this integration is not “all or nothing.”
Traceability can be scaled based on your
business strategy, anywhere from jumping
in head first to taking a more phased imple-
mentation approach.
Due to its projected growth, we expect
to see a significant increase in adoption
of IIoT-enabled traceability among manu-
facturers in the coming years. As technol-
ogy grows, so will our ability to harness it
to improve our productivity and the world
around us. ✺
DAVE SWEET (dave.sweet@mecco.com) is
president of MECCO, Cranberry Township,
9001:2015
PA; www.mecco.com.
NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 21
11/6/18 8:23 AM
 t e c h n o l o g y r e p o r t

Laser materials processing

AS LASER MATERIALS PROCESSING

APPLICATIONS BECOME MORE

expanding material selections while increasing throughput to
CHALLENGING, DIGITAL SERVOS MUST meet large volume demands. Converting requires close track-
ing for quality kiss cuts with faster web speeds. And close
STEER LASER BEAMS WITH HIGHER tracking is of vital importance to laser additive manufacturing,
as it maintains consistent power density on the processed
PRECISION, FLEXIBILITY, AND FINESSE
medium to provide high-quality parts.
For each of these applications, the digital control servo
THAN THEIR ANALOG PREDECESSORS
driver has made it possible to reach new levels of performance,
largely because of the State Space Model and its key advan-
ERIC ULMER
tages over analog servos.

State Space Model and Observer overview

O
The State Space Model runs the control loop with input from
ver the past two decades, the a model of the galvanometer (also known as galvo) and mir-
use of laser processing for ror. The galvo is an electromechanical device that can be rep-
medical, imaging, marking, resented by differential equations that relate the galvo’s elec-
and manufacturing applica- trical and mechanical parameters. For example, the galvo’s
tions has grown exponentially. induced current is derived from the coil’s resistance, induc-
This growth is supported by tance, and back electromotive force (EMF) constant, while the
advances in the beam-steering galvo’s rotor acceleration is derived from its torque constant,
technologies that make these applications possible and the inertia, and friction.
unique requirements for each application motivate the devel- In State Space theory, the electrical current and rotor
opment of new control techniques for servomechanism (servo) acceleration are examples of states in the galvo system’s
drivers that steer the laser beams. model. A fully defined State Space Model for a galvo sys-
For many years, the analog servo driver has been the bench- tem could have more than 10 states. Together, these states
mark for performance, with its flexible tune configurations pro- model the interdependency of the galvo parameters and
viding targeted performance the relationship between the
at an attractive price and form Command Error Voltage Galvo + Acceleration system’s input, current state,
Controller
factor. However, an increasing – mirror future state, and output.
number of applications have State space Position The State Space Model
specific performance require- model sensor incorporates real-time system
ments that are best met with Calculated Measured feedback to stay aligned with
feedback feedback
digital technology. the actual system response.
State vector
f(x) This feedback is brought into
feedback
Digital servo Observer the State Space Model using
advantages an Observer (FIGURE 1). Every
Servo performance require- FIGURE 1. Shown is the typical control loop used within an time the actual drive voltage is
ments are being driven by key Observer-based digital servo. applied to the real galvo, a sim-
applications such as mark- ulated voltage is applied to the
ing and coding, micromachining, converting, and additive model of the galvo to generate its current state. The Observer
manufacturing. combines the measured system feedback with calculated feed-
Marking and coding is looking for higher throughput in terms back, and outputs a correction feedback to the controller.
of more characters per second (CPS) without degrading qual- Since the State Space Model provides insight to the future
ity and/or supporting higher conveyer speeds with similar state of the system, it allows for predictive positioning control.
CPS. Micromachining pushes to maintain precise features in For example, if the model knows the required acceleration for

22 Industrial Laser Solutions NOVEMBER/DECEMBER 2018 www.industrial-lasers.com

1811ILS_22 22 11/6/18 8:23 AM

g drives new servo
control technologies
the next state of a system, it can determine if it is within its Typical galvo systems have tracking delays between 100
physical limits. If the drive capability is insufficient, the com- and 1000 µsec. The marking job file must add compensation
mand input can be modified to stay within physical limits of the time for these delays to maintain pattern quality, and this lim-
system. In the following sections, we explore how this exam- its throughput.
ple of command optimization can improve marking through- The digital servo reduces this tracking delay by 50–100%
put from 30% to 100% over analog servo technology without without giving up stability. With knowledge of the galvo and
sacrificing mark quality. mirror dynamics accurately captured in its model, the con-
trol algorithm within the digital servo optimizes the input com-
a) Analog servo mand profile to limit the acceleration to a value that will keep
40,000 the servo within drive voltage limits. As a result, the additional
Angle 20,000
(cc) 0 filtering can be removed to greatly reduce the tracking delay
-20,000
-40,000 for increased throughput.
Time (s) 0.000 0.001 0.002 0.003 0.004 Command In some cases, the digital servo control algorithm can elim-
Position
b) DC3000 Plus inate the tracking error completely. For example, the DC3000
40,000 Plus digital servo driver introduces a small delay in the com-
Angle 20,000
(cc) 0 mand stream. It uses this delay to analyze the command
-20,000
-40,000 stream and smooth areas of high acceleration. It then dynam-
Time (s) 0.000 0.001 0.002 0.003 0.004

a) DC3000 Plus @ 1275 cps

FIGURE 2. Tracking delays introduced by typical analog Digital servo
servos (a) are eliminated by the digital DC3000 Plus servo (b).
1275 cps JS=MS=11 m/s, JD=40 µs, MD=20 µs, PD=30 µs, LON=0, LOFF=50 µs, PIP=430 µs

Predicted response, optimized commands b) Analog servo @ 1275 cps Digital Servo

With an accurate digital model of the galvo system in place, Analog servo
the control loop can be manipulated to achieve the correct 1275 cps JS=MS=11 m/s, JD=40 µs, MD=20 µs, PD=30 µs, LON=0,
AnalogLOFF=50
Servo

balance of speed and accuracy. Much of the speed increase
comes from the digital servo’s ability to predict the system’s
response to a command input.
In some digital servo designs, feedforward terms are added,
which pre-distort the command to improve system response
time while still maintaining stability and accuracy. In other
digital servo designs, the system bandwidth is dynamically
adapted as needed and applies the full drive capabilities to
keep the galvo response aligned closely with the command.
In both approaches, the system tracking delay is reduced.
Digital servos and zero tracking delay
Traditional marking generates vector patterns using veloci-
ty-limited commands. Because of large acceleration require-
ments at the vector end points, the analog servo driver must
include filtering to add a delay in the galvo’s response to a
given command, limiting the amount of drive voltage required
to change speed and direction. This delay is referred to as the
system’s tracking delay, and is directly related to the system’s
step response time and maximum linear speed.
FIGURE 3. Characters marked by
a laser on marking paper have
significantly higher quality when
using a digital servo (a) compared ically adapts the band-
to an analog servo (b). width, when necessary,
to apply all of the avail-
able drive voltage to lock
onto the post-processed command, eliminating the tracking
delays (FIGURE 2).
Using zero-tracking-delay algorithms, micro-precision fea-
tures in the pattern that would normally be limited by the servo
bandwidth are now limited only by the drive voltage, allowing
up to 2X faster speeds for the smallest features in marking,
micromachining, and trepanning. Applications like converting
and additive manufacturing also benefit by the fact that con-
sistent laser energy density is applied at corners and other pre-
cision features in the pattern.
Benefits of the reduced tracking delay are highlighted by
comparing the character quality produced by laser marking
using an analog servo with that of the DC3000 Plus digital

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 23

1811ILS_23 23 11/6/18 8:23 AM

 t e c h n o l o g y r e p o r t

servo driver running the same 6220H galvo and 10 mm mirror The analog servo tuning process varies considerably with the
configuration at equal mark/jump speeds and delay settings type of control architecture and the specific criteria for each
(FIGURE 3). application. The flexible tuning strategies for the analog servo
The relatively small delay settings have been optimized for the require significant user experience before tuning proficiency is
digital servo driver and achieve marking speeds of 1275 CPS. To achieved, and are typically performed by highly trained techni-
obtain similar character quality using the analog servo driver, the cians using expensive test equipment. As a result, analog servo
delay settings would need to be increased by nearly 3X and result tuning is almost always performed by the servo board supplier
in marking speeds of 900 CPS. Note that the optimized command and this tends to limit field serviceability options.
from the digital servo still maintains all Auto-tuning of the digital servo driver
the critical features of the original pat- greatly simplifies the tuning process, making
tern, so the mark quality remains high Pre-tune Post-tune it far more accessible to new users. It also
while increasing throughput by 40%. enables flexible inventory control: since the
Position Position
digital servo can be tuned at any time, it can
Auto-tuning overview Current Current be delivered separately from the galvo and
The State Space Model also enables mirror in efficient quantities. For example, if
auto-tuning capability. Most digital ser- a configuration differs only by mirror coating
vos include this feature, which pro- Expected Actual
type, the laser tool manufacturer could redi-
vides several benefits for production rect the galvos and servo to the appropriate
quality, integration flexibility, and field coated mirror as demand requires. In contrast,
serviceability. FIGURE 4. In the auto-tuning process, analog servos would require the complete gal-
The Observer is used both during actual system feedback is compared to vo-servo-mirror configuration to be available
closed-loop operation and for auto-tun- the model’s expected results to adjust in inventory for both mirror coating types.
ing. During closed-loop operation, the model parameters; shown is the system Field service is simplified with auto-tuning
Observer is being used to make slight response before (a) and after (b) the auto- in that the process requires very little technical
corrections in the control loop, whereas tuning process, whereby the top curve input for successful calibration. Once the field
during auto-tuning, the Observer is used shows position and the bottom curve service person has identified the faulty com-
to make corrections to the galvo model. shows current. ponent, they only need to replace the defec-
The auto-tuning process starts with tive part and initiate the re-tuning process.
a predefined model of a galvo saved in the servo’s memory. This confines the component removal to only what is needed
When a new a galvo is connected, the digital servo captures and leaves the rest of the configuration in a ready-to-run state,
the unit’s frequency response and other system parameters minimizing customer downtime and making replacement compo-
to update the model. This is followed by a fine-tuning process nents easier to stock. In the same scenario, analog servos would
where the Observer compares the model’s expected response to require the entire configuration to be replaced and returned to
that of the actual galvo, and the model parameters are adjusted the factory for repair and re-tuning.
through multiple response iterations until the expected and actual
response closely match each other. At that point, the system is Enhanced monitoring and system protection
considered tuned (FIGURE 4). Using the digital galvo’s model and its thermal resistance, the
power dissipated in the galvo can be continuously monitored to
Simplified production and field service verify that the temperature remains within safe operating limits.
The galvo system must be closely aligned to the model’s default The servo can also use the thermal model to incorporate changes
state for the auto-tune process to complete successfully. For this in the galvo’s model as it heats up during operation. Since the gal-
reason, auto-tuning can help identify marginal components during vo’s resistance, inductance, and torque are all affected by higher
the assembly process. For example, large shifts in the resonant power dissipation, the servo can compensate for the changes in
frequency could indicate an improperly installed mirror. High noise these parameters to keep the settling response consistent from
levels during the fine-tuning process could point to a marginal cable initial power-on to high duty-cycle operation.
connection. In short, auto-tuning is a comprehensive verification Digital servo technology continues to enhance existing
step to ensure high-quality assemblies. and emerging laser materials processing applications. Next-
In contrast to the digital servo, the analog servo tuning pro- generation digital servos are expected to improve and support
cess is largely isolated from component-level variations. The tun- new application requirements. This could include better model-
ing process is essentially monitoring the position feedback of a ing, faster update rates, higher resolution command and posi-
black box system while adjusting the servo gain terms to achieve tion feedback, predictive maintenance algorithms, integral sys-
the desired response to a pre-determined command input. As tem safety checks, and enhanced synchronization to system
long as the tuning terms can be adjusted to achieve the desired controllers and lasers. ✺
response, the system is considered verified. Even experienced
ERIC ULMER (eric.ulmer@cambridgetechnology.com) is a product manager at
tuners may not see a slight shift in resonant frequency from a Cambridge Technology, a Novanta company, Bedford, MA; www.cambridgetechnology.com.
marginally attached mirror.

24 Industrial Laser Solutions NOVEMBER/DECEMBER 2018 www.industrial-lasers.com

1811ILS_24 24 11/6/18 8:23 AM

 a p p l i c a t i o n r e p o r t

Indian laser market

maintains growth
trend
INDUSTRIAL LASER SOLUTIONS EDITORIAL

ADVISOR REPORTS FROM INDIA

ANANT DESHPANDE

TMesse Muenchen India.

he annual LASER World of
PHOTONICS India (LWoP
India) trade fair was held
September 26-28, 2018, at
the Bangalore International
Exhibition Centre (BIEC), and organized by

This year’s show was much larger and bet-

ter than last year, with more than 150 exhibitors
from 13 countries. Exhibitors included lead-
ing players Trumpf, Coherent, IPG Photonics,
Laserline, and Precitec, all making their pres-
ence felt. Integrators such as Suresh Indu,
Scantech, Sahajanand Ahmedabad, Meera

Laser, and Bradma were also

present with their live demon-
strations apart from leading
representative companies
in India that include Laser
Science, Advance Photonics,
ATOS, AMIL, and Precitec.
The show had German and
Chinese pavilions where, for
example, Scanlab demon-
strated its excelliSCAN scan-
ning system and Raycus show-
cased its 6 kW fiber laser.

www.industrial-lasers.com NOVEMBER/DECEMBER 2018 Industrial Laser Solutions 25

1811ILS_25 25 11/6/18 8:23 AM

 a p p l i c a t i o n
Participation from Chinese companies
was quite visible, as half of the show’s sec-
ond hall featured laser companies includ-
ing Raycus, Max Photonics, Shenzhen
JPT Opto-Electronics, and CAS Laser, and
complete machine suppliers such as Bodor,
HSG (through their representative Laser
Technologies), and CK Laser, all with big
booths and demonstration machines rang-
ing from fiber lasers to fiber marking, 3D
engraving, and UV laser marking systems.
At the show, we saw customers and
delegates from various fields and indus-
try-leading companies such as Honda,
Titan, and Volvo. There were also visitors
from government labs such as the Indian
Space Research Organization (ISRO),
Bharat Electronics Limited (BEL), and oth-
ers, suggesting that LWoP India is gaining
in popularity every year.
This year, two conferences were held.
One was the Additive Manufacturing
Summit by show organizer UBM, and the
other was on Smart Manufacturing with
Lasers. At the latter, keynote speaker Dr.
1811ILS_26 26
r e p o r t
Sri Venkat, senior vice president and gen-
eral manager of high-power fiber lasers at
Coherent, talked about the company’s new
HighLight FL-ARM (adjustable ring mode)
fiber laser and how it is helping to improve
the welding process in applications such as
automotive, battery, and others. Speakers
from other companies presented the lat-
est technologies offered by their respective
companies, such as Trumpf, Laserline, and
Coherent, and the solutions they offer for
the industrial market—mainly automotive.
This year, there were also talks from laser
end-users such as TATA and JBM.
Going around the show and talking
to different suppliers and manufactur-
ers, it looks like laser marking and cut-
ting machines may become a commodity
market in the coming years, as the selling
prices for these products are dropping
drastically year after year. It will be inter-
esting to watch how this market unfolds
in coming years—right now, the market
is growing rapidly, and it is dominated by
Chinese suppliers.
Like other markets, the laser market in
India also has its own challenges for stan-
dard laser marking and cutting machines.
It looks, however, that applications such
as welding, cladding, and micromachin-
ing are starting to pick up.
Speaking to Carlos Lee, Director
General of the European Photonics
Industry Consortium (EPIC), we talked
about laser technology in the Indian mar-
ket and its growth. He mentioned that
EPIC is helping technocrats from different
parts of world to get together to share the
knowledge on different photonics appli-
cation among each other.
Last but not least, we saw India’s
first 3D metal printing machine made by
Scantech—kudos to Nilesh Ramani and
his team.
Overall, the Indian Laser market looks
buoyant, promising, and competitive. ✺
ANANT DESHPANDE (anant_deshpande20@
yahoo.com) is an Industrial Laser Solutions
Editorial Advisory Board Member focused
on laser processing in India.
11/6/18 8:23 AM
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NOVEMBER 5-8 International Trade Fair for Machine

28-29 LAF 2018 – Laser Applications Tools, Manufacturing, and Automation
FOR SUBSCRIPTION INQUIRIES: Toll-free: 1-800-869-6882; International Callers: (INTEC), Leipzig, Germany; www.messe-
1-512-982-4277; Fax: (866) 658-6156; ils@kmpsgroup.com; web: ils-subscribe.com
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IN EUROPE: Mailfast, JFK/BOS/850858, P.O. Box 66, Hounslow, United Kingdom anwenderforum
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Group Publisher Alan Bergstein 4 IPG FiberForum, Marlborough, MA; Germany; www.automotive-circle.com/en/
(603) 891-9447 • alanb@pennwell.com www.ipgphotonics.com/en/event/ conferences/eala-european-automotive-
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Associate Editor Lee Dubay
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Creative Director Meg Fuschetti JANUARY 2019 lia.org/conferences/ilsc
Production Manager Sheila Ward 4-7 3rd International Conference on
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Advertiser ............................................................................................................. Page
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1811ILS_27 27 11/6/18 8:23 AM

 my view
Market turbulence produces
industry agita
T
his is the time of year when we are
busy preparing the 2018 Annual
Economic Review of the indus-
trial laser market that will appear
in the January/February 2019 is-
sue. Long-time readers are aware of previous
columns on the vagaries of this process. In es-
sence, even in this era of warp-speed commu-
nications and bottomless online resources, we
CHINA’S
are still in the thralls of time and can’t juggle it in
our favor. Simply put, the key numbers we need
INDUSTRIAL LASER for verification of 2018 public company financial
performance won’t be available for verification
MARKET TOPS until early in 2019, long after we will have pub-
lished our review.
You may well ask, “How does Industrial Laser
CONCERNS
Solutions [ILS] get around this?” Or better yet,
“why must the ILS Economic Review appear in
the January/February issue?” I’ll answer the lat-
ter first—the initial issue of the year, by ILS tradi-
tion, contains the review of the preceding year. We
can’t do it in November/December issue, as final-
year data is not available. Simple?
As for the former, we rely on published com-
ments by industry leaders. In our case, guid-
ance for 2018 financials issued by public corpo-
rations as best estimates for the coming quarter/
year. For industrial lasers, we look for financial
data from two of the four members of the Billion-
dollar Club: IPG Photonics and Coherent, which
between them last year reported about 50% of
total industrial laser revenues. The other two are
Trumpf, a privately held company, and Han’s
Laser, which to my knowledge does not publish
guidance numbers.
This year, a concurrence of beyond-their-con-
trol economic factors plagued industry leaders
IPG Photonics and Coherent (both have lost about
half their stock value in six months), causing us to
28 Industrial Laser Solutions NOVEMBER/DECEMBER 2018
1811ILS_28 28
be alert when reading their corporate guidance
numbers along with comments made in their earn-
ings calls and other published reports. For exam-
ple, as this column is being written, IPG Photonics
announced that expected third-quarter revenues
would be lower than previous guidance, as will be
full-year revenue growth. Coherent has a broader
product line than IPG Photonics with both com-
mercial and scientific research products, but in
recent weeks this company’s stock price has lost
half its value, presumably on concerns with indus-
try tariff barriers on manufacturing products and
currency exchange.
In our view, of most concern to the industrial
laser product suppliers is China, both as a mar-
ket and as a potential source of competition.
This country has a burgeoning global market for
industrial laser processing systems, mainly fiber
laser-powered flat sheet cutting machines. The
Chinese government has shown funding support
for domestic laser product companies that have
developed IP that will enable these companies to
compete on a global stage. The key is domestic
IP, in product design and performance. Already,
domestic fiber laser manufacturers and process
and control software developers have eyes on the
large and profitable international market.
Companies such as IPG Photonics and
Coherent, which have a large percentage of reve-
nues emanating from China, are fine-tuning their
businesses to adapt for shifts in the China mar-
ket and for potential new competition. Observers
suggest the timing on this may have stretched out
as a result of global tariff and currency actions.
David A. Belforte
belforte@pennwell.com
www.industrial-lasers.com
11/6/18 8:24 AM
1811ILS_C3 3 11/6/18 8:22 AM
1811ILS_C4 4 11/6/18 8:22 AM