Download the OP2 Datasheet.

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

 
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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.

Feature Highlights

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.

Specifications

Laser

  • 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)

Optical Configuration

  • 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

Scan System

  • 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

Manipulator

  • 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

Exhaust System

  • 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

Enclosure

  • 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

Control

  • 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)

  • Upgradable software

Calibration Sensors

  • 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