Laser Beam Welding (LBW) finds widespread use in industries like naval and automotive. To meet the demands of complex welding processes, higher power lasers have been developed. However, conventional refractive optics limit power utilization, affecting robustness. Multi-Plane Light Conversion (MPLC), a fully reflective technology, enables complex beam shaping with 16kW lasers. A MPLC-based laser head with an 800µm annular shape at 1µm wavelength has been developed. LBW of 304L stainless steel (6mm thick) at 7kW and HLAW of steel (16kW) with 23mm penetration depth are successfully demonstrated. MPLC's extended depth of field improves welding efficacy, showcasing its potential in advancing laser welding applications.
Laser Powder Bed Fusion (LPBF) is a critical additive manufacturing process known for its accuracy and complexity in producing intricate parts. However, challenges like limited production speed, hot cracking, and material restrictions hinder its efficiency. This study explores the use of Multi-Plane Light Conversion (MPLC) as a beam shaping solution to improve LPBF. By applying MPLC, we achieve faster printing while maintaining high-quality parts. Comparative analysis demonstrates the superiority of MPLC-based beam shaping in enhancing process yield and manufacturing efficiency.
Beam shaping has gained increasing importance in laser-based processing, offering enhanced efficiency, quality, and precision across various applications. This paper discusses the challenges of characterizing and defining criteria for evaluating shaped beams in laser material processing. It highlights the essential role of beam shaping in Continuous Wave (CW) processes like high-quality welding for e-mobility and pulsed applications like surface texturing. Various beam shaping technologies are explored, and criteria such as efficiency, uniformity, sharpness, robustness, and depth of field are proposed for evaluating beam performance. Proper characterization and evaluation of shaped beams are crucial to optimize laser performance, ensuring reliable and repeatable outcomes in laser-based processes.
Laser welding is crucial for manufacturing e-mobility components, particularly copper and aluminum parts. However, their high reflectivity and thermal conductivity present challenges, leading to inadequate penetration and weaker welds. Beam shaping offers a promising solution by modifying the laser beam's intensity distribution. In this study, we demonstrate successful welding of aluminum battery cases, copper busbars, and hairpins using Multi-Plane Light Conversion for beam shaping. Results show improved weld quality, reduced defects, and enhanced mechanical properties. The technique provides a higher depth of field and an extra degree of freedom for optimizing weld quality, promising efficient and reliable manufacturing of e-mobility components.
Satellite constellations, whether for high-speed Internet access or for Earth observation using high-resolution imagery, are leading to a sharp increase in the volume of data to be brought back to Earth. To meet the needs of these very high-speed communication links, from 10 Gbps to 1 Tbps, optical technologies are becoming essential. Radio frequency technologies currently in use can no longer cope with such data rates without threatening the allocation of frequencies on Earth (5G-6G) or in space. However, to work at high debit rates, broadband optical communication systems require small detectors, high performance amplifiers or coherent modulation schemes needing high efficiency coupling into SMFs, which is subject to atmospheric turbulence. Using Cailabs' core technology, Multi-Plane Light Conversion (MPLC), followed by a photonic integrated chip optical recombiner, we have developed and qualified a unique component for turbulence compensation. This architecture provides high-speed turbulence mitigation at several kHz with the advantage of a single SMF output. In this paper, we investigate the fading improvement provided by this system over direct single mode fiber coupling under various environmental conditions and technical implementations. This system is tested on a km-long test link at Cailabs at up to 10 Gbps under appropriate environmental conditions and at higher debit rates on a turbulence emulation bench. Several configurations are evaluated, including several levels of turbulence. Meanwhile, Cailabs is building its first optical ground station for the LEO-ground optical link. We will present the first experimental results obtained and the roadmap for satellite-ground communication.
Space-to-ground laser communication is booming thanks to high throughput, stealth communication without frequency allocation. However, lasercom becomes really competitive beyond 10 Gbps. At this rate, fiber components, requiring SMF coupling, and thus turbulence mitigation become necessary.
Based on Cailabs' core technology, Multi-Plane Light Conversion (MPLC) followed by photonic integrated chip, Cailabs develops a turbulence mitigation product entirely dedicated to lasercom. Previous work showed proof of concept for the 8-mode version. In this article we investigate last results obtained with the system including 100 Gbps communication and present the new 45-modes turbulence mitigation version.
We demonstrate turbulence mitigation in a free-space optical link without adaptive optics. A module consisting of an 8-mode Multi-Plane Light Conversion (MPLC) device connected to a photonic integrated chip (PIC) collects a perturbed beam and converts it into a fundamental mode propagating in a standard single-mode fiber (SMF). Module is tested on a 200-meter optical link at 1550 nm under different D/r0 conditions. Results are compared to simulations and laboratory experiments using calibrated turbulent phase plates. We show increased coupling efficiency and lower fading compared to SMF coupling, demonstrating that MPLC and PIC are a viable turbulence mitigation option.
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