The Civan Lasers (Jerusalem, Israel) Dynamic Beam Laser has now been installed at the Fraunhofer Institute for Beam and Material Technology (Fraunhofer IWS; Dresden, Germany), the first research institution worldwide to use such a laser solution for industrial use.
Using “coherent beam combining” technology, the 13 kW laser can generate energy distribution patterns thousands of times faster during operation compared to conventional mirror-based methods, making it possible to use dynamic beam shaping for additive manufacturing of metals. Together with project partner Civan Lasers, Fraunhofer IWS scientists hope that the testing will provide new application scenarios.
The Dynamic Beam Laser combines tens of individual beams into a powerful laser beam with high quality. Through small phase shifts, the laser can quickly generate completely different energy distribution patterns in the resulting processing laser beam. While a classic laser releases most of its energy only in the center of the beam, the Dynamic Beam Laser system can generate energy patterns on the workpieces—for instance in the form of a ring, a figure eight, or a horseshoe. In principle, this was already possible in the past with beam-deflecting optics or fast oscillating mirrors, but even the fastest oscillating mirrors still need milliseconds to realign the energy patterns in the beam. The Dynamic Beam Laser, however, accomplishes this within microseconds.
This speed makes it possible to use dynamic beam shaping for additive manufacturing of metals. As part of the ShapeAM research project within the M-era.Net European network program, researchers are testing the new Civan Lasers system to achieve improved material properties. Specifically, the aim is the additive manufacturing of titanium and aluminum alloys, such as those needed for space components, implants, and lightweight components for mobility. In doing so, the partners plan to use dynamic beam shaping to eliminate defects and thus achieve higher quality 3D printing results.
The tests at Fraunhofer IWS are intended to determine the possibilities and limits of the Dynamic Beam Laser. Basic tests with various beam profiles, materials, and processes are initially planned. After that, the researchers will evaluate concrete applications, such as how well the system can cut, join, or additively manufacture diverse workpieces from materials and material composites that are otherwise difficult to process.
It is already predictable that the new laser will allow faster and more precise control of the melt pool dynamics in many additive and joining processes—and not only across the surface, but also in depth. Fraunhofer IWS also expects advantages in laser cutting in terms of burr-free cuts with high edge quality, at twice the working speed compared to conventional fiber lasers.