Lasers are essential tools for a wide variety of materials processing applications. The speed, quality, and process window are determined in part by the laser beam properties, including size, shape, and divergence. Most laser sources have fixed beam characteristics, resulting in processing and material limitations and nonoptimized performance. nLIGHT has developed a fiber-laser product line that provides rapid tunability of the beam characteristics directly from the delivery fiber using a novel, all-fiber mechanism. The broad range of beam sizes and shapes and real-time programmability allow adjustments on-the-fly and optimization of each process step using a single laser source, enabling development of versatile tools that provide optimum performance for a range of processing needs. We describe the underlying technology, performance, and beam characteristics and show results for the largest industrial laser applications, including metal cutting, welding, and additive manufacturing.
Next-generation industrial fiber lasers enable challenging applications that cannot be addressed with legacy fiber lasers. Key features of next-generation fiber lasers include robust back-reflection protection, high power stability, wide power tunability, high-speed modulation and waveform generation, and facile field serviceability. These capabilities are enabled by high-performance components, particularly pump diodes and optical fibers, and by advanced fiber laser designs. We summarize the performance and reliability of nLIGHT diodes, fibers, and next-generation industrial fiber lasers at power levels of 500 W – 8 kW. We show back-reflection studies with up to 1 kW of back-reflected power, power-stability measurements in cw and modulated operation exhibiting sub-1% stability over a 5 – 100% power range, and high-speed modulation (100 kHz) and waveform generation with a bandwidth 20x higher than standard fiber lasers. We show results from representative applications, including cutting and welding of highly reflective metals (Cu and Al) for production of Li-ion battery modules and processing of carbon fiber reinforced polymers.
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