Mr. Cloots, our customer from the Institute of Rapid Product Development (IRPD), tested the new Vortex DOEs with a donut profile and provided LASER COMPONENTS with his feedback!
Laser Components (LC): Where do you use these elements?
Institute of Rapid Product Development (IRPD): We work on the further development of generative manufacturing processes with the goal of introducing products more quickly onto the market. We use this DOE in selective laser melting (SLM). In this process, metallic powder is fused to a shape using an NIR laser.
LC: Why do you use Vortex DOEs?
IRPD: The laser beam used has a TEM00 Gaussian profile. When applying new metallic powder, the previously fused material is damaged again. This is caused by the simple fact that the intensity in the center of the laser beam is too high for this application. In an older unit, in which we work with an undefined laser beam, we received better results.
Thus, it is our goal to improve the SLM process in the new unit by shaping the laser beam. The use of diffractive optics is uncritical: we do not have to make any modifications – neither to the laser nor to the whole system.
LC: What made you think of using a diffractive optical element?
IRPD: As part of a workshop, we discussed the option of using a DOE with a donut profile with product engineers from LASER COMPONENTS. Ms. Herdt ultimately advised us to try a Vortex DOE.
LC: Have you tested other alternatives to beam shaping?
IRPD: Yes. Tests were originally performed with conventional beam shapers that turn a Gaussian profile into a top hat. However, in the prevalent working environment, it was impossible to optimize the process significantly.
LC: Were there advantages to using the Vortex DOE?
IRPD: LASER COMPONENTS lent us an element at short notice and we were able to run the first tests: Through beam shaping, we expect to see lower tension in the material – the first tests were promising! We not only solved the problem with the center intensity that was too high but are able to use its additional advantages: With the Vortex DOE, the laser beam does not penetrate as deeply into the material. At the same time, the beam cross section is somewhat larger; this allows the process to be carried out more quickly and thus economically!
LC: You would, therefore, use this element again in the future?
IRPD: Definitely. We have meanwhile purchased our own element and will run more tests. We see advantages to using Vortex DOEs in other areas of laser material processing – whether in welding, cutting or drilling.
LC: Mr. Cloots, we would like to thank you for the interview and look forward to more test reports from your team.
