In Part 1 and Part 2 of our series on Fiber Laser Integration, we learned about fiber optic lasers and compelling technologies developed by our strategic technology partner, TRUMPF. However, integrating fiber optic lasers into an R&D or production environment is more complex than plug-and-play. Developers need help asking the right questions to select and integrate a laser solution best suited to their application.
In Part 3, let’s look at how AC helps guide the process of successfully integrating a fiber optic laser into your manufacturing line.
Successful Fiber Optic Laser Integration Demands Multiple Analyses
Buying a fiber optic laser solely on its isolated technical specifications does not guarantee success. Because the laser is just one part of your overall manufacturing process, making the right selection depends on many factors and requirements.
As engineering integrators, our role is to help you determine the suitability and impact of the technology on your overall production line. As we complete a thorough set of analyses, we focus on the laser system best suited to deliver on your manufacturing requirements.
Let’s look at some of the crucial questions we use to drive the right decisions.
| Analyses | Performance Requirements | Determinations That Drive Decisions |
|---|---|---|
| Assess Application Requirements | Material Type and Thickness Level of Precision Quality of Cut or Mark |
How will materials absorb laser energy differently to determine the choice of laser power and wavelength? What level of precision, quality, and stability is required of the fiber optic laser beam? How much power output is required to achieve efficient production rates? (E.g., for laser marking, we might start at a few watts or move up to several kilowatts for laser cutting and welding of thick materials.) Which beam mode should be prioritized for your specific manufacturing outcome (single-mode for finer quality or multi-mode for faster processing)? |
| Determine Laser Specifications | Wavelength Power Output Beam Quality (M² factor) Pulse Characteristics |
What is the right laser light wavelength for your material processing task? (e.g. most metal processing is between 1,060nm and 1,070nm because metals efficiently absorb these wavelengths). For applications requiring high precision, which technology delivers the lowest M² value for the high beam quality the task requires? For precision marking or engraving, what should the pulse duration, frequency, and energy be to best manage heat input and material response? |
| Evaluate Laser Source and System Configurations | Type of Fiber Laser System Integration Compatibility Scalability and Upgradeability |
Which type of fiber optic laser is right for the manufacturing process? (e.g., continuous wave for cutting and welding or pulsed for marking and fine engraving?) Can the laser system be integrated with existing or new automation systems? Is there software compatibility with the control system? What are the scaling limitations or possibilities? |
| Consider Operational Costs and ROI | Energy Efficiency Maintenance Requirements Downtime and Reliability |
Although fiber lasers are inherently efficient, how does the proposed laser solution meet the manufacturing efficiency requirements? Although lasers typically have extremely low maintenance, do they meet the specific maintenance and long-term operational requirements and costs? Does the system enable the right level of productivity in the automated environment? Does the laser system deliver both high reliability and low downtime? |
| Conduct Tests and Prototypes | Material Testing Prototype Development |
What tests need to be run on actual or similar materials to observe how the laser interacts and achieves the desired outcomes? What prototypes need to be developed to ensure the final setup meets all requirements effectively? |
Revealing Hidden Roadblocks with Fiber Optic Laser Integration
In addition to a thorough set of technical analyses, successful integration also involves detecting potential roadblocks ahead of your investment in fiber optic laser manufacturing.
Because we are motivated by your automation success and not the sale of any particular technology, we are invested in objectively revealing and solving any potential roadblocks. This is vital not only to the success of your deployed laser technology today but also for future scaling and versatility.
Here are some examples of potential roadblocks we can help you solve in advance of buying and deploying a fiber optic laser system.
| Roadblocks to success, scaling, and versatility | Solutions through automation engineering |
|---|---|
| Manufacturing is poorly defined; steps are overlooked like fixturing and inspection | Create a checklist to fully vet the complete manufacturing process. How is the material presented before, during, and after the laser processing stage? Is there pre- or post-inspection to integrate as a part of the entire process? Define all of the specifications, not just the laser's suitability, before determining the true manufacturing speed and application requirements. |
| Technology is incompatible or difficult to integrate with other components and systems | Examine and vet compatibility with control software and other tools or systems. Develop a thorough proof-of-concept plan to ensure successful integration into new and existing manufacturing lines before landing on the right fiber optic laser solution. |
| Fixture complexity is inadequate for the level of precision performance and complexity of part(s) | High-precision applications require tight tolerances. With laser drilling and cutting, small angular position changes make big changes in hole diameter. Design a precise fixture with an optimal orthogonal position to the laser for the exact focal distance. |
| Challenges are presented using one fiber optic laser with two or more dissimilar materials | With a single laser processing multiple types of materials, identify ways to optimize performance for changes in material properties, like rigidity or strength. |
| Mismatched laser-to-vision technologies | Consider adding external vision that is independent of any onboard laser vision. Adding an off-axis inspection tool enables a clear picture of the true position of the laser. Select a vision camera with high optics to match the frequency of the laser. |
| Cleanroom and environmental requirements are impacted by laser operations | Ensure the operating environment has proper ventilation and filtration suitable for the laser operation. For example, laser ablation of plastics requires mitigating the resulting vaporization and fumes. |
Ready for AC engineering support to successfully integrate a fiber optic laser?
Complex fiber optic laser applications and manufacturing processes require more planning and engineering design than an off-the-shelf laser system can deliver. We can support not only the integration of your laser technology but also your end-to-end product development and automation journey.
Take advantage of engineering insights and analyses by letting AC Automation help you avoid costly roadblocks to success. Let’s talk!
