High Accuracy Step-and-Scan Micromachining
for fast and precise processes in 2.5D and 3D
Flexible and Modular Machine Concept
from single purpose production machine to all-round laboratory workstation
High Level of Automation and Sensor Integration
allows the user to focus on the application instead of on the machine
Flexible and Scalable control Software
enabling large and complex machining programs
Lightmotif's OP2 is a 5-axis laser machine tool designed for surface texturing and micromachining on complex 3D curved workpieces. The combination of step-and-scan machining and a state-of-the-art picosecond laser provide the best combination of speed and accuracy for applying micro-features to relatively large parts. The system can be used as a flexible workstation for R&D or as a production system. Based on a modular machine concept the OP2 can be adapted to create a semi-custom machine that fits the requirements specific to your application.
Large area laser surface micro-texturing
The OP2 is specifically designed for micro-texturing of large and heavy (up to 300 kg) workpieces. The step-and-scan machining method and built-in scan field calibration ensure accurate tile alignment (negligible stitching errors).
The use of a picosecond laser source enables machining of very small and detailed features. Dimple textures can be made with dimple diameters as low as just a few micrometers. Free-form pockets allow for example the machining of small pillars, and the typical material interaction of ultrashort laser pulses enables applying different types of micro roughness.
By using control software developed by Lightmotif specifically for large and complex step-and-scan micromachining jobs the system allows programming textures which contain millions of small features.
Details handled automatically
Ideally the operator should never have to worry about machine-specific details, but instead focus on those directly relevant to the process. For example, to mark a line should not require thinking about scanner mirror acceleration or tracking errors. Lightmotif uses various sensor systems to allow the machine to handle these details automatically.
An automatic power calibration system allows programming in physical units (watt) instead of laser "relative" power, avoiding the need for manual power measurements, and ensuring a program will always yield reproducible results.
To achieve maximum accuracy from the scan head the system is equipped with a tool calibration system. This camera-based system automatically measures and corrects for scan head alignment errors, scan field distortion, scan system and laser pointing drift, and variations in the laser focus.
JDSU PicoBlade® picosecond micromachining laser
10 ps pulse width
1064 nm wavelength, (auto-switching) 532 and 355 nm options
Fast modulation of pulse energy (up to 2 MHz)
Wide range of repetition frequencies (up to 8 MHz) and pulse energies (up to 200 µJ)
Telecentric objectives with 80 or 100 mm focal length, 160 mm focal length non-telecentric
Scan field ranging from 45×45 to 110×110 mm
Spot sizes from 7 to 70 µm (depending on wavelength and optics)
Variable beam expanders for spot size adjustment
High accuracy SCANLAB 2D scan system with digital encoders for low drift and dither
Scan head aperture of 14 or 10 mm
Quick exchange scan head mounting system for easy switching between wavelengths or objectives
5-axis motion platform with granite base body
Separate stage for built-in calibration sensors (power, alignment)
Air bearing direct-drive linear stages with repeatabilities better than 1µm
Large air bearing rotary stage supports products of up to 300 kg
600×600 mm working area
400 mm Z axis travel
Integrated local fume and particle extraction system moves with the scan head to ensure optimum capture efficiency for 3D machining
Enclosure ventilation using filter fan units to provide clean air downflow
Free standing laser safe enclosure with interlocked doors
Easy access to work table and scan head
Additional large doors can be used when loading large/heavy workpieces
Beam shaping area can be accessed from within the enclosure, allowing alignment / adjustment without requiring additional laser safety measures
Job definition using high level programming language (Python) scales to large and complex jobs
programmable control of laser settings (repetition rate, burst)
Graphical job preview and inspection
Automatic power calibration, i.e., jobs are programmed in watt instead of percentage
Graphical operator interface
Support for system control by third-party software (C API, network protocol)
High resolution off-axis camera allows precise position measurements in the image plane as well as in the focus direction
Camera system offers greater than 1×1 mm color image with an optical resolution of 1.5 µm at a large working distance of more than 55 mm
Integrated power calibration system measures the laser power and system transmission to ensure process repeatability
Automated scan field calibration system measures and compensates field distortion and drift, and determines the exact scan field location