Ultrafast lasers, also known as ultrashort pulse (USP) lasers with pico- and femtosecond ranges, are often known for their ultra-precise excision and cutting results. However, material processing with such lasers takes a considerable amount of time.laserpecker 2 laser engraver To address this problem, a new research project funded by the European Commission aims to increase the speed of material processing using ultrafast lasers by up to a factor of one hundred.
Ultrafast lasers have a unique ability: they can ablate virtually any material without imposing a thermal load on neighboring materials. They remain smooth and melt-free, even with micron-sized cuts. All of these characteristics make ultrafast lasers very attractive in industries such as toolmaking,laser pecker 4 where hard materials must be machined with great precision.
A new laser engraver is now capable of producing antifouling, hydrophobic metal or plastic surfaces that could soon replace toxic paints used in marine coatings to stop algae or barnacles from sticking to the hulls of ships, thus reducing maintenance costs,laser pecker pro fuel bills and CO2 emissions.
Utilizing new photonics technology, a group of European scientists are currently developing a 1kw fractional ultrafast laser system that mimics shark skin by sculpting metal or plastic surfaces to create surfaces with better hydrodynamic effects.
The new laser system can etch tiny "spike" structures into metal or plastic, creating a rough surface at the microscopic level. This uneven surface reduces drag and inhibits the growth of bacteria, algae and even barnacles.
A shark's skin is covered with millions of tiny particles (tiny raised scales), a design that reduces drag and makes it an efficient swimmer. Similarly, sculpted metal or plastic surfaces can be "anti-fouling", preventing pollutants or microorganisms from adhering to them.
The scientists behind the €4.7 million laser project hope that generating specially designed structures on steel hulls could help reduce fuel consumption and replace environmentally harmful toxic marine paints.
"Laser-created surface structures have the potential to reduce friction and prevent the growth of plants and algae. This can significantly reduce ship repairs, maintenance, CO2 emissions and fuel costs while replacing environmentally toxic and harmful paints."
"In addition to offshore components, areas of application can also be found in aircraft and turbomachinery. Here, surface structures may inhibit cavitation and thus increase the service life of propulsion systems or turbine propellers."
Ultrafast lasers can ablate any material without damaging it. Surfaces cut with ultrafast lasers are micron-smooth, making them ideal for many industries that require high-precision machining of hard materials.
Like an old-fashioned dot-matrix printer that prints line by line, the laser sends out ultra-fast pulses of concentrated energy to ablate or cut hard-to-machine materials.
The system resembles a giant checkerboard that divides a single beam into a grid of 64 "mini-beams," any of which can be turned on, off, positioned and individually adjusted.
"Existing ultrafast lasers are known for their precise ablation and cutting effects. Unfortunately, machining large parts with such lasers can take weeks. Our system is capable of ablating more than 150 cubic millimeters in less than a minute, making it hundreds of times faster than existing technology."
Ultrafast lasers represent an exciting breakthrough in surface technology with a wide variety of applications:
Tool and Die Manufacturing - With increased production volumes, it is now possible to produce USP tool and die manufacturing equipment for applications such as making vents or micro-cavities, and making texturing on free-form surfaces more cost-effective. Tool and die making equipment was the first area to validate the technology.
Automotive - Microstructure applications for interior lighting, instrument panels, and aesthetic and haptic structures by providing high throughput for USP surface treatment technology.
Electronics - The proliferation of USP technology in electronics will improve the performance and reliability of complex, high-performance electronic components. Manufacturing of USP-based through-holes and technical ceramics for high-performance electronics will be significantly improved.
Printing and Imprinting - With more economical and faster production lines, USP printing systems have the potential to significantly increase the efficiency of electronic printing, precision imprinting of microstructures, and high precision tooling.
