Company insight
Precision laser solutions for material processing
Material processing would be inconceivable without lasers, especially in the medical devices space where precise cuts and strong welds are paramount to product performance and patient safety. Brent Roeger, laser applications engineering manager, IPG Photonics, explains how the Massachusetts-based company can support customers everywhere, from manufacturing to R&D.
Can you briefly explain the depth of experience IPG Photonics has developed in the materials processing space? Brent Roeger: First and foremost, IPG’s core technology involves laser material processing using fibre lasers. The most common applications include welding, cutting and precision drilling. We are also involved in laser ablation, selective material removal and even laser lift-off, for instance for processing flexible electronics. We operate across a large number of industries, ranging from medical devices to defence. Add in the different materials that are involved, various exotic metals and a variety of polymers as well as project requirements for process quality, and things can become complicated quickly. With that in mind, we have developed a range of lasers to support customers, including continuous wave (CW), nanosecond pulsed and even ultrafast lasers. IPG’s materials processing systems business then integrates our laser and beam delivery technology into turnkey laser workstations – all optimised for specific production requirements. At the same time, we are continually improving our understanding of materials processing. We often find we can cross pollinate what we have learned from one industry or application to another, resulting in superior solutions for our customers.
Has the rapid development of medical devices and the push towards miniaturisation posed any challenges for manufacturers in this space? Can you give an example? As parts get smaller, more precision is needed. Motion control is, therefore, an obvious need here. But equally important is precision in laser power control, as well as capabilities in beam delivery techniques.
Variations in part fixturing, and part-to-part variations in the workpiece itself need to be addressed too. A good example would be hermetic welding of pacemakers, where control of the heat input is critical to a successful weld.
Can you explain how your solutions, for example ultrashort pulse lasers, can mitigate these difficulties? This technology has really advanced over the past several years, both in terms of performance and cost, both areas where IPG continues to innovate. A great example is stent and tube cutting. The exceptionally high peak power of the ultrashort pulse laser results in significantly reduced thermal damage, smaller features and better control when compared to longer pulse duration lasers. For the manufacturer, the benefits include reduced post processing, while the smaller cut widths allow engineers to better optimise part designs for improved bending characteristics.
Beyond the lasers themselves, how important are workstation capabilities here, and how have you integrated technology like vision systems and real time process monitoring to prevent errors and bolster yield? The workstation needs to incorporate technology that is appropriate to manufacturing requirements and balances requirements for process capabilities, part yields and throughput. Ultimately, it must provide a good return on investment. Vision systems allow us to automatically align to parts or even to individualise features on parts. This is not limited to XY positioning, but also rotational alignment and for focus corrections prior to processing. This results in more consistent processing.
Medical Device Developments /
www.nsmedicaldevices.com
Systems like our real-time weld monitoring technology use a low-power measurement laser – together with the welding laser – to measure key parameters like weld penetration depth. By allowing QA procedures to be streamlined, our customers can respond immediately to quality issues, and ultimately craft excellent products.
With polymer processing increasing in popularity, how does that impact how you think about your products, and what does it say about the flexibility of your R&D? Polymers play a very important role in medical device manufacturing. For applications related to melting, such as precision cutting, we have green and UV lasers in nanosecond or ultrafast pulse durations. At the other end of the spectrum, when looking at polymer welding, we have developed mid-IR lasers. This longer wavelength is ideal for clear- to-clear polymer welding: well suited to medical devices where darker polymers or additives are undesirable.
How do your applications labs help customers keep abreast of this fast- moving industry going forward? Our applications labs are equipped with state-of-the art laser processing equipment. Customers will also find experienced engineers with deep knowledge in materials processing, and who can discuss the advantages of different technologies. Testing your materials allows us to optimise recipes and allows you to inspect process quality. This can sometimes be an iterative process. But once a process is refined, we can offer a laser system that is tailored to your needs. ●
www.ipgphotonics.com 63
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