Leading up to the Laser Institute of America’s 50th Anniversary in 2018, I decided to visit longtime industry partners around the country to get a firsthand look at innovations within the laser
Trumpf Factory (Photo by Jim Naugle)
industry. I was impressed with many of our allies; advancements in the additive manufacturing industry, significant leadership shifts and refreshing concepts seemed to be the common narrative. However, one company took the cake when I visited their 50,000 sq. ft. technology center in Hoffman Estates, Illinois, Nov. 2017. TRUMPF GmbH, a laser systems manufacturer based in Germany, designed and built this $30 million USD manufacturing facility with the future in mind.
Their state of the art manufacturing and consulting location will educate costumers interested in digitally connected production while showcasing Industry 4.0 Solutions. During my tour of the facility, Jens Kappes, the chief engineer of the Smart Factory, explained that the factory is designed to produce parts using the latest production technologies and strategies.
“TRUMPF Inc. always strives to find new ways to innovate and stay at the forefront of Industry 4.0,” said Kappes. “The TRUMPF Smart Factory is not only a showroom, but also a production site focusing on the entire sheet metal process chain. Every machine is important, but creating an optimized process where everything works together is what we call TruConnect, and critical to an Industry 4.0 facility. The ultimate goal of the Smart Factory is to help our customers introduce digitally connected production solutions into their own facilities. Our Smart Factory intelligently connects the entire sheet metal process chain, and not only improves our own processes but serves as a model for customers to improve their own.”
The organization chose prime real-estate, because according to their website, approximately 40 percent of North America’s sheet metal is processed in the Midwest. This means TRUMPF GmbH
Trumpf Factory (Photo by Jim Naugle)
can better serve customers in the U.S., which is the company’s second largest market after Germany.
The custom built edifice is unique because its architectural design is directly tied to its day-to-day functionally. They didn’t build this beautiful structure to house production, they built it to monitor, adjust and appreciate production in its entirety. It features a self-supporting steel ceiling covering a 55 meter production hall; skywalks that offer a birds eye view; and a futuristic control room that would make Tony Stark proud.
“It was a pleasure to have Jim visit our facility in Illinois and learn about our technology,” said Tobias Reuther, director of TRUMPF’s Smart Factory. “The relationships we foster and maintain with other organizations are important to us. They’re not only critical to our success, but to driving education and growth within our industry.”
I have visited many of TRUMPF’s facilities around the word and each time I leave, I say to myself, “Wow! That’s how you do it!”
From customer service to production ingenuity; Illinois is no different. It truly represents what the future of manufacturing will be and you can see it working to perfection. It’s a must visit for all manufacturing enthusiasts, laser focused or not.
The brilliant light of the laser promises unlimited possibilities for materials processing. Its use in manufacturing dates back to the late 1960s where laser drilling was developed for jet engine components. As laser technology has progressed, fast-paced advances in computers and sensor technologies have enabled the development of improved process monitoring devices which has further enhanced the performance, reliability and ease of use of industrial laser systems.
In 2014, the total global market for laser systems for material processing which include both the source and the components was $9.2 Billion (Source: Optech Consulting, VDMA). From this, the total global laser source revenue was $2.9 Billion, according to the data presented by Industrial Laser Solutions (Feb 2016). In 2015, this revenue (only the global laser source revenue) increased by 6.9% to $3.2 Billion. Although, the largest market share has been and continues to be (61% in 2015) in the laser cutting and laser marking/engraving, their % year-over-year growth has been limited to <5%. More interestingly, the higher % Y-O-Y growth areas are laser welding (17%), laser surface treatment (31%) and laser additive manufacturing (71%).
Courtesy Image
In this article, we present a clear view of how advances in laser power and beam quality along with a significant drop in laser cost per watt and improved laser wall plug efficiency has contributed to major innovations in laser material processing. We have identified four broad laser processing segments and analyzed what is driving innovation.
Manufacturers in many industries have long used laser welding to tackle traditional welding challenges, but laser welding technologies are evolving for even greater utility. Hybrid welding where laser welding is combined with other conventional arc welding methods such as GMAW (MIG) and GTAW (TIG), laser welding with filler wire, and part pre-heating have been successfully implemented in Industry. This has been possible now due to the availability of higher power lasers at lower cost. In turn, materials that were considered difficult to weld until now such as higher carbon steels and cast iron can now be successfully laser welded. The additional filler material changes the composition of the weld, preventing the formation of hard and brittle microstructures. Likewise, induction preheating can be used to help prevent cracking due to martensite formation by slowing down the cooling rate after welding. For instance, in an automotive transmission part, a bolting process was replaced with laser welding, cost savings were achieved through reduced material and processing costs (drilling operations / bolting operations and the bolts themselves), and an overall part weight reduction was accomplished with a more efficient production method using laser technology.
Laser welded transmission part versus traditionally bolted assembly (Courtesy image)
Laser remote welding(Courtesy image)
Remote laser welding is another laser welding process which dramatically reduces welding process cycle times compared to conventional welding and is now possible due to availability of higher beam quality lasers and high speed scanners. It involves the use of moving optics in order to rapidly scan the laser beam across the workpiece over large distances both for high speed and for high precision point to point movement.
To capture the higher potential of laser welding, there has been substantial yet continuous development in laser welding head technology which includes the welding optics themselves and also the sensor optics. Some of these process monitoring technologies have been in development for some time. Some are not yet ready for application at scale. But camera based laser monitoring is now at a point where its greater reliability and lower cost is starting to make sense for high power welding applications.
Fraunhofer CLA has developed a high speed camera vision system which can record the welding process in high clarity in real-time and provide both image and video data from the process. This information is processed and calibrated with reference data based on pre-determined actual ‘good’ weld measurements using reinforcement learning. Using customized image processing software algorithms, it is possible to detect many of the most common weld defects.
One laser processing technology which has recently been moving up to forefront of innovative, or even disruptive technologies is laser additive manufacturing (LAM). This process uses laser beam as heat source and is primarily divided in two processes: Selective laser melting (SLM) and Laser metal deposition (LMD).
In the SLM process, a layer of powder is deposited on a build platform and then a rapidly scanned laser beam fuses powder together in the right shape and multiple thin powder layers are deposited to create complex 3D parts.
Fraunhofer Coax wire deposition head allows multi directional build up using wire. (Courtesy image)
In the LMD process (also known as direct energy deposition or laser cladding), the laser is used to melt metal powder fed through the nozzle which is then deposited in layers onto a substrate, which results in a full metallurgical bond with a small heat affected zone and minimal dilution. It has been developed for surface wear and corrosion coatings, component repairs/remanufacturing, and generation of complete components from scratch.
Fraunhofer process monitoring system hardware (Courtesy image)
Two other variations of LMD—hot/cold wire cladding and internal diameter cladding—have now evolved into successful industrial processes and are now widely used in the oil industry, agriculture, power generation and remanufacturing sectors. A recent key development by Fraunhofer IWS is a new coax laser deposition head COAXwireTM which provides
omni-directional welding performance for the use of metallic wires as filler material which is of particular use for 3D build up additive manufacturing of metallic components.
One area of laser material processing that has benefitted the most from technology improvements in both spatial and temporal properties of the laser is laser machining. In addition, the advent of lower cost and smaller footprint laser power sources has lead to much wider industrial adoption of laser technology. The latest generation of pulsed lasers with pulse lengths—from millisecond all the way to femtosecond—has led to a rich pipeline of innovations impacting virtually every manufacturing industry. For example, laser cutting of battery electrodes can produce excellent cut quality and achieve high cutting speeds for application in lithium-ion battery cell production. Similarly lasers can be used for coating removal for electrical contacts on battery foils. Large area coating removal for paint stripping, deoxidization, mold and die cleaning or removal of special coatings is conducted by applying high power lasers. Lasers are also used for high rate drilling process for up to 15,000 holes/second.
Fraunhofer high speed camera system software (Courtesy image)
In summary, the current pace of innovations leading to new laser technologies and products is constantly increasing with a wide array of new applications being developed for every industry imaginable.
Craig Bratt, Executive Director, Fraunhofer USA, Center for Laser Applications, cbratt@fraunhofer.org
Rahul Patwa, Project Manager, Fraunhofer USA, Center for Laser Applications, rpatwa@fraunhofer.org
Laser Institute of America presented Professor Reinhart Poprawe, managing director of Fraunhofer Institute for Laser Technology (ILT), the Peter M. Baker Leadership Award during this year’s International Congress on Applications of Lasers & Electro-Optics (ICALEO®) in Atlanta, Georgia, Oct. 22-26.
Lin Li (right), former LIA president, presented LIA’s Peter M. Baker Leadership Award to Professor Reinhart Poprawe(left), at ICALEO, Oct. 25 in Atlanta, Georgia.
The award acknowledges individuals who demonstrate outstanding leadership in an organization while significantly benefiting the laser community. It is named after former LIA executive director, Peter M. Baker, who led LIA for almost three decades.
“There is no question that Professor Poprawe richly deserves this award. In our world of lasers, he is a leader on the grand scale, technical, organizational, political and social,” Baker said. “He is a fine gentleman, courteous, thoughtful, generous and funny. I consider it an honor to be his friend.”
Poprawe’s professional expertise includes laser applications, laser additive manufacturing, and photonics in life science. Additionally, he has a great deal of experience in laser development and plasma technology in the realms of process analysis, sensors for laser processes, laser induced plasmas and more.
“The award is from one of the most important laser communities in the world,” Poprawe said. “It is a great honor to receive this award as the first recipient after the original, Mr. Peter Baker himself.”
According to several of his peers, Poprawe has been an important figure within the industry for decades.
Professor Reinhart Poprawe addresses a crowd at ICALEO, Oct. 25 in Atlanta, Georgia.
“Professor Poprawe has been an important figure here at LIA for years,” said Nat Quick, LIA’s executive director. “He has been an LIA board member since 2001 and he always steps up when it counts most. He served as an LIA president in 2012 and has functioned as editor-in-chief of the Journal of Laser Applications® (JLA) since 2010. He is incredibly generous and exemplifies what it means to be a leader.”
After earning his Physics Ph.D. in Germany, Poprawe worked as the laser-oriented process development department head for Fraunhofer ILT before becoming their managing director. Additionally, he holds the university chair for Laser Technology at the RWTH Aachen University.
“There are so many ingredients for a successful organization,” Poprawe said. “Vision; mission; research and product portfolios; roadmaps; SWOT-analysis; and education of the employees. Industry or even better societal use and implementation of our research results is what we do everything for, especially the development of the demanding competencies in the very fundamentals of Laser Technology and application Physics.”
About LIA
The Laser Institute of America (LIA) is the professional society for laser applications and safety serving the industrial, educational, medical, research and government communities throughout the world since 1968. www.lia.org, 13501 Ingenuity Drive, Suite 128, Orlando, FL 32826, +1.407.380.1553.
Orlando, FL – September 28, 2017 – The Laser Institute of America (LIA) announces the technical program and conference highlights for the 36th annual International Congress on Applications of Lasers & Electro-Optics (ICALEO®). Industry visionaries, technical specialists, researchers, end users, and equipment manufacturers will convene at the Sheraton Atlanta Hotel in Atlanta, Georgia, to explore advances in laser applications happening today in a wide variety of industries October 22-26.
“I am honored to have worked with the most innovative minds in laser applications to bring ICALEO’s program to life,” said congress general chair, Christoph Leyens, of TU Dresden and the Fraunhofer IWS in Dresden, Germany.
The opening plenary session explores medical and climate applications while giving a glimpse at new laser tools. The session will surely push the limits regarding traditional views of laser applications:
Mark Schnitzer, an associate professor at Stanford University, and investigator at the Howard Hughes Medical Institute, works in neural circuit dynamics and optical imaging. His optical innovations are used to further neuroscience studies worldwide.
University of Colorado department of physics professor, Dr. Henry C. Kapteyn, builds new tabletop “x-ray laser” light sources and helps develop corresponding applications.
Jeff Deems is a researcher at CIRES, the National Snow and Ice Data Center in Boulder, Colorado where he also serves as the liaison for the NASA Airborne Snow Observatory. Deems specializes in laser mapping snow packs and developing lidar applications for avalanche forecasting and climate applications.
To close ICALEO, Dr. Leyens has invited plenary speakers from two groups that are spearheading adoption of additive manufacturing.
The accelerated certification of additively manufactured metals initiative director at Lawrence Livermore National Laboratory is Dr. Wayne King. He will discuss how his team is leading the transition from conventional manufacturing methods to metal additive manufacturing.
Florian Bechmann, head of Engineering & Technology (Concept Laser brand) at GE Aviation will explore technologies that advance manufacturing of jet engines and other airplane components using new tools such as additive manufacturing.
ICALEO has a strong emphasis on Laser Materials Processing and in recent years technical presentations have integrated additive manufacturing, often known as 3D Printing, with traditional subtractive technologies like cutting, drilling, and marking, as well as with welding, inspection and optical analysis. Sessions delving into the specifics of laser applications were organized by:
Laser Materials Processing Conference Co-Chairs: Klaus Kleine, Coherent Inc. and Friedhelm Dorsch, TRUMPF Laser- und Systemtechnik GmbH
Laser Microprocessing Conference Co-Chairs: Michelle Stock, mlstock consulting and Cather Simpson, University of Auckland
Nanomanufacturing Conference Chair: Yongfeng Lu, University of Nebraska-Lincoln
Additionally, the conference offers a number of casual opportunities to meet new colleagues, connect with old friends, and share knowledge. From the opening music-filled Welcome Celebration, to the President’s Reception, and the Vendor Reception, ICALEO offers a wealth of fun networking events.
“ICALEO serves as a great platform for learning and networking,” said Gus Anibarro, LIA Education director. “You don’t get this kind of crowd anywhere else in the world. The attendees are made up of top-tier laser scientists and educators.”
The LIA Annual Meeting and Awards Luncheon to be held on Wednesday, October 25, will be a highlight of the community. This year the prestigious Arthur L. Schawlow Award will be presented to Dr. Paul Seiler, former managing director of TRUMPF Laser GmbH. The recognition is in honor of his pioneering work utilizing lasers in machine tools for industrial applications. Dr. Seiler joins luminaries in the field of lasers including Milton Chang, Reinhart Poprawe, and Steven Chu, who were past recipients.
No conference in this day and age can be successful without sponsorships. IPG Photonics Corporation; EdgeWave GmbH; Innovative Laser Solutions; SPI Lasers; TRUMPF Inc.; Laserline Inc.; Light Conversion Ltd.; Lumentum; and Spectra-Physics, A Newport Company, have all demonstrated a commitment to furthering laser utilization in real-world applications by supporting ICALEO.
The Laser Institute of America (LIA) is the professional society for laser applications and safety serving the industrial, educational, medical, research and government communities throughout the world since 1968. www.lia.org, 13501 Ingenuity Drive, Suite 128, Orlando, FL 32826, +1.407.380.1553.
Gilbert Haas founded Haas Laser Technologies Inc. in 1992. From its inception, he wanted the company to exemplify innovation, reliability and quality above all else. Additionally, he aimed at producing laser beam delivery components, which would define industry standards.
“Our products include laser beam delivery components, laser beam diagnostic equipment and custom laser systems,” said Gilbert Haas, president of Haas Laser Technologies.
Haas Laser Technologies facility in Flanders, NJ. (Photo courtesy of Haas Laser Technologies Inc.)
The company has approximately 20 employees who work out of three key locations: Florida, Washington and its main facility in New Jersey. International distributorships support the company’s products worldwide.
Haas mentioned that the corporation, which turns 25 this year, has witnessed sustained growth since its inception. As a result of this growth, their products are currently utilized around the world in all industrial laser applications.
Haas ensures his company is postured for innovation by remaining engaged within the laser manufacturing community. In fact, he was an integral part of the LIA Board of Directors from 2014-2016 and currently serves as the LIA Executive Committee Treasurer.
“Being a member of the LIA puts you on the cutting edge of technology,” said Haas. “Whether it be conferences at ICALEO, LAM, LME, or via proceedings, online courses and certifications, you can always be sure LIA has the information you need to succeed.”
Haas keeps a close eye on where industry trends are headed so that his organization can better adjust to customer needs. The company is an innovator, was a Prism Award finalist several times, and holds several national and international patents.
TLC Optics (Image courtesy of Haas Laser Technologies Inc.)
“Many new efforts are being made in the laser field,” said Haas. “We have seen the evolution of Nd:Yag to Fiber Lasers and the advances in CO2 laser technology. Being on the forefront of the
BWA-CAM (Image courtesy of Haas Laser Technologies Inc.)
technology keeps us energized. We are always challenged with developing new unique products that open new markets.”
According to Haas, the Laser Diagnostics and TLC product lines are the latest product offerings by Haas Laser Technologies Inc. today.
“Our BWA Laser Measurement System is the world’s fastest and most repeatable system for laser beam measurements,” stated Haas. “Our TLC optics mitigates thermal lensing experienced in optics in high power laser systems.”
For more details about Haas Laser Technologies Inc. please visit www.HAASLTI.com
This Corporate Member Feature was written by Brandon Kalloo in collaboration with Haas Laser Technologies Inc.
