The Kern Femto E3 is a 3-axis femtosecond laser micro-milling system based on a proven high-precision motion platform and state-of-the-art laser micro-machining control software. The system is designed for accurate laser micro-milling of small workpieces, specifically for shaping of stamps and press tools.

Conceived as a production system, the system is compact and made for use in a shop floor environment. Optional automation allows (unmanned) stable serial production. The system is easy to operate – detailed knowledge of laser processes is not required to use the machine.

 

Features and benefits

Excellent form accuracy enabled by Adaptive Machining technology.

Long term accuracy by automatic machine calibration systems.

Fast and cost effective machining especially for hard materials like cemented tungsten carbide.

Digital production easy and digital CAM workflow.

Sustainable low energy consumption, no consumables, low-noise emission.

 

Feature Highlights

Automated calibration

Automated spot position and power measurements on the work table are used to keep the machine in calibration and compensate for drifts in the spot position or the laser power. This guarantees accuracy as well as stable and reproducible results.

Adaptive machining

The machined depth is measured during machining and deviations are compensated automatically. This significantly reduces the depth error in laser micro-milling, especially of deeper structures.

Advanced laser processes

Laser processes specifically developed for machining cemented tungsten carbide offer both speed and precision. Material removal rates of 1 mm³/min or higher can be achieved. Depending on the application, form accuracies of ±5 µm or better are possible, and the surface roughness can be as low as 0.1 µm (Sa) or better. The ultrashort pulse laser process has a very small heat-affected zone with no significant sub-surface damage, which increases the tool life.

 

Specifications

Laser

  • Amplitude Satsuma HP2 industrial micromachining laser

  • 1030 nm wavelength

  • 350 fs to 10 ps pulse width

  • High repetition frequency (up to 40 MHz)

  • Fast modulation of pulse energy (up to 2 MHz)

Scan system and optical configuration

  • High accuracy SCANLAB 2D scan system with digital encoders for low drift and dither

  • Telecentric objective with 125 mm focal length

  • 50×50 mm scan field

  • 30 µm spot diameter 

Manipulator

  • High precision 3-axis motion platform
    (built on the proven Kern Evo machine platform)

  • Integrated workholding system (EROWA ITS 100)

  • Euchner motion pendant for manual control

Control

  • Proprietary control software specifically designed for laser micro-machining

  • Sensor based adaptive machining

  • Easy to use task oriented HMI

  • Laser micro-milling CAM software

Calibration

  • Integrated power calibration system measures the laser power and system transmission to ensure process repeatability

  • Automated scan field calibration system measures and compensates distortion and drift, and determines the exact scan field location (tool offsets)

  • Integrated distance sensor for measuring workpiece heights and for adaptive machining

  • High optical resolution off-axis camera allows precise position measurements in the image plane as well as in the focus direction

  • Machine drift compensation

Enclosure

  • Laser safe and X-ray safe enclosure with interlocked doors

  • Easy access to work table

Dimensions and weight

  • Weight: 3,200 kg

  • Machine dimensions (W×D×H): 1.5 m × 1.5 m × 2.2 m

Exhaust system

  • Integrated local fume extraction system moves with the scan head to ensure optimum capture efficiency

Automation

  • Optional external workpiece changer