Development of a Laser Micromachining Process for the Fabrication of SiC Mirrors
Summary:
Laser micromachining offers the ability to machine products with significant automation while also requiring less post processing and enabling machining that is impossible with conventional equipment. Mound Laser & Photonics Center (MLPC) is developing new techniques to use laser micromachining to produce objects such as mirrors and 3d parts for medical devices. The company is unique in its approach to commercialization, as it aims to make 50 percent of its revenue through commercial services.
Technology Description:
MLPC uses an 8 W laser system that emits laser pulses only 10 picoseconds in duration. The time between pulses is adjustable down to 20 nanoseconds of separation. MLPC is currently the only commercial laser micromachine shop in the country to use this quarter-million dollar laser system.
This laser system can machine features on the order of a few microns over a 12 by 12 inch area. Essentially, the laser operates like an adjustable drill bit, capable of being 5 microns in diameter, up to a few tens of microns in diameter.
In comparison, traditional micromachining uses tool bits that are one or two thousandths of an inch, and they tend to break, dull, and have various other problems. Lasers do not dull and need very little maintenance.
The techniques being developed by MLPC are capable of creating 3 dimensional structures that could be used in a variety of industries. Automation using the micromachining technology could change many fields, including the polishing of mirrors used in missile defense application.
MDA Origins:
MDA and other government entities are interested in replacing beryllium components, such as mirrors, with other materials because beryllium is hazardous to work with, dramatically increasing costs. Silicon carbide is being examined as a possible replacement for beryllium, but requires new processing technologies. MLPC has received Phase II SBIR and STTR awards for developing laser micromachining techniques for fabricating a mirror shape out of silicon carbide.
MLPC will study material removal rates of the picosecond laser on silicon carbide mirror blanks and determine if laser micromachining can process a mirror blank into near final form in an automated process. The finished product will be suitable to go to final polish.
Spinoff Applications:
The first application for this technology is the production of mirrors for the MDA and other defense clients. However, MLPC suggests that there are potential customers, especially in the medical device industry, for very small 3D structures made by laser micromachining.
Commercial uses for laser micromachining focus on the techniques ability to produce very small objects very efficiently and in a highly automated fashion. This enables the manufacture of much smaller devices. The company indicates that while the demand for such small parts is small, it will grow when the capability is introduced to manufacturers.
One area that MLPC is focusing on is the medical device field, where smaller devices are extremely important, and accurate manufacturing is essential. The company already serves this market with laser welding and some laser micromachining.
Commercialization:
MLPC provides laser micromachining, as well as laser welding and marking to customers as a service and the company is not in the business of selling finished products.
However, the company intends to commercialize its MDA research as soon as possible and is committed in deriving 50 percent of its revenues from commercial services in laser marking, welding, and micromachining. Last year, revenues were approximately $1 million. Currently micromachining makes up a small part of their commercial business, but it is growing as other manufacturers become away of the MLPC’s capabilities.
MLPC indicates that customers have used their micromachining services to develop prototypes that may turn into production volumes if they turn into products. In addition their micromachining techniques will continue to improve as the company develops new techniques for its R&D customers, such as the MDA.
The processes are currently guarded with trade secrets as there are significant barriers for entry into this field and much of MLPC’s business is based on their expertise and experience.
Company Profile:
MLPC was started in 1995 as part of the commercialization of the Department of Energy’s Mound Laboratory nuclear weapons facility. In February, 1998 MLPC was acquired by Laser Fare, but founder and president, Dr. Larry Dosser, purchased the company back from Laser Fare in 2002 to pursue laser micromachining. The company currently has 20 employees, 11 or which are full time and nine are part time. Most of the part time employees are students from local colleges and universities, and several of them will be employed full time after they graduate during the next year. The company has two share holders, the majority is held by Dosser, and one employee is a minority shareholder.
Contact Information:
Dr. Larry R. Dosser
Mound Laser & Photonics Center, Inc
P.O. Box 223
Miamisburg, OH 45343-0223
937-865-4481
fax: 937-865-3680
email: dosserlr@mlpc.com
web: www.mlpc.com
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