Simply Brighter: High Brightness Direct Diode Industrial Lasers. Fabtech 2012

Transcription

1 Simply Brighter: High Brightness Direct Diode Industrial Lasers Fabtech 2012

2 Introduction: wavelength beam combining Our TeraDrive direct diode technology has the unique competitive advantage of high brightness high efficiency low cost high reliability Our technology can scale to a Terawatt/cm 2 -str, equivalent to >10kW from a singlemode fiber We hold 8 exclusive licenses from MIT for the key technologies, plus more than 8 patent applications of our own 1

3 Company Background Management Parviz Tayebati, PhD, CEO, founder of CoreTek, (Nortel), Azna (Finisar), Independent Investor/ Entrepreneur Bien Chann, PhD, CTO, co-founder of TeraDiode and formerly from MIT LL Kevin McCallion, VP of Engineering, formerly from CoreTek and Finisar Jay Liebowitz, VP of Sales and Marketing, formerly from Teem Photonics and Lasertron Damon Pender, CFO, Voice Signal Robin Huang, PhD, VP of Defense Programs, co-founder of TeraDiode and formerly from MIT LL Investors Stata Venture Partners Argonaut Equity Partners Camros Capital 2

4 Wavelength Beam Combining Enables Material Processing using Direct Diode Lasers TDI s direct diode lasers Diode laser pumps Gas laser Fiber laser Doped fiber gain medium Nd:YAG laser Doped rod gain medium Disk laser Doped disk gain medium Welding, annealing, cutting and drilling of ferrous and nonferrous Rod Sheet Tubing Bar Semifinished parts CO 2 filled discharge tube WBC direct diode lasers eliminate the brightness converter middlemen, producing simpler and more efficient lasers 3

5 TeraDiode Vision of Material Processing Lasers First Gen. Second Gen. Third Gen. - Co2 (10um) - YAG (1um) - Fiber Laser (1um) - Disk Laser (1um) - Wavelength Beam Combined Direct Diode (Any diode wavelength) Smaller More Efficient Lower cost of ownership 4 4

6 Wavelength Beam Combining Technology Invented at MIT LL for high-brightness pumping of high-power fiber lasers (DoD) MIT and TDI improvements enable high efficiency, low cost, and use of commercial, off-the-shelf (COTS) laser diodes Many versions: can be optimized for spatial brightness, spectral brightness, or both 5

7 TeraDiode Intellectual Property on WBC Number Title Ownership US2009/63101 High Power Multi-Wavelength External Cavity Laser Beam Combining of Diode Laser Array Elements for High Brightness and Power External cavity laser source using spectral beam combining in two dimensions External Cavity 1-D Wavelength Beam Combining of 2 Diode Laser Elements Exclusive License from MIT Exclusive License from MIT Exclusive License from MIT Licensed from MIT Four other MIT patent applications on related technology to WBC Eight patent applications from TeraDiode TeraDiode s IP covers all fields of use, including industrial and defense applications 6

8 Wavelength-stabilized diode laser bar characteristics V PCE P L-I-V of passively cooled diode laser bar Power Conversion Efficiency (PCE) at 50 A = 51% Diode laser efficiency above 55% WBC efficiency as high as 90% Wavelength stabilized to nm 7

9 High efficiency laser module PCE P V Fiber coupled version of 500W module Free-space output laser module with >560 W Beam quality suitable for coupling into 100 mm or 50 mm fiber PCE at 85 A = 48% 8

10 TeraDiode s industry leading brightness Company Power (W) Fiber (mm/na) - Stabilized Brightness (MW/cm 2 -sr) TDI 2000 W 2,030 50/0.11 Yes 2730 TDI 1000 W /0.14 Yes 778 TDI 450 W /0.10 Yes 194 Commercial Diode Laser 1 Commercial Diode Laser 2 Commercial Diode Laser 3 2, /0.10 No /0.10 No /0.12 No 28 Over 50x higher brightness than the state-of-the-art in direct diode lasers Comparable brightness to kw-class industrial diode pumped lasers 9

11 WBC TeraBlade: 2kW from 100µm fiber >2,000W out of processing fiber (95% coupling out) 100µm/3.75mm-mrad WPE: target >40% (Higher efficiency means lower cost) 10

12 High Power Industrial Lasers: Measured Beam Quality versus Power 1000 Beam Quality (mm-mrad) Lamp pumped SSL CO 2 lasers Fiber lasers Disk lasers Power (kw)

13 TeraDiode 1kW laser used for cutting steel 1.6mm thick 304 stainless steel at 54 /min (1.28m/min) 1kW launched from 200 micron, 18 mm-mrad delivery fiber Edge quality comparable to industrial CO 2, solid state, and fiber lasers Power Fiber Brightness 6.65mm thick (0.26 inch thick) sheet of mild steel Specs 1,040 W 200 µm/0.18 NA 31 MW/cm 2 -str Date September

14 TeraDiode laser welding cross sections 800W on work piece Nitrogen cover gas Weld is 2 long Speed is 0.8 in/sec Bead on order of wide Keyhole welding of 304 stainless steel Cross-section results courtesy of Geoff Shannon, Miyachi-Unitek 13

15 TeraDiode meets or exceeds competition Price/performance comparison for a typical 2 kw laser module, 50µm, 0.11NA fiber Fiber Disk Diode Brightness (MW/sr/cm 2 ) 2,682 A 2,682 B 2, Wall-plug efficiency (inverse relationship to cost) >40% B 30% 18% 25%- 40% Operating cost ($/hour) C $1.00 $1.57 $2.24 $1 - $2 Notes: A. Based on processing fiber (singlemode brightness much higher) B. Assumes 90% efficiency for laser driver C. Based on 9 cents/kw-hr in US (Michigan) 14

16 TeraDiode meets or exceeds competition Price/performance comparison for a typical 2 kw laser module, 50µm, 0.11NA fiber Fiber Disk Diode Wavelength selectability Any diode None None Sensitivity to backreflection Any diode None High Low None 15

17 Higher Efficiency from Wavelength Beam Combining Lowers Total Cost of Ownership Starting from light emitted by the diodes WBC has at least 80% efficiency (Wall Plug Efficiency = 40%) versus Fiber laser efficiency of 60% (WPE = 30%) Higher efficiency translates into real savings The laser itself Fewer diodes needed to generate the laser light Lower Bill of Material cost Less power lost to heat Multiplier effect that reduces chiller requirements Lower power consumption Smaller footprint 16

18 500W Fibered Engine DLE W laser engine BPP < 3.75 mm-mrad 20 microsecond rise and fall times with separately supplied TeraDiode control electronics 500W DLE 486 x 71 x 246 mm 3 (D x W x H) Free space beam before fiber 500W DLB 17

19 TeraBlade Product Platform Product Implementation is a combination of: Wavelength Beam Combining (Teradiode core competency) Spatial beam combining Polarization Beam Combining Dichroic Beam Combining (coarse WDM) 500W WBC Blade 976nm 976nm 976nm 1060nm or 6kW, 8kW, 10kW SBC SBC SBC SBC SBC SBC SBC SBC PBC PBC PBC PBC 2kW, 50um 4kW, 100um Dichroic Optical Beam Combiner 4kW, 50um 18

20 TeraBlade Laser System: DLS Designed for easy maintenance and lower cost 0.8 x 0.8 x 0.9 m 3 (D x W x H including casters) 19

21 High reliability designed in Design strengths Using laser diodes with over 100,000 hours of Lifetime (MTTF: 440khrs) Reliable Free Space Opto-mechanics Using reliable power supplies and controllers Advantages over alternative laser technologies No couplers that have power density limits No splices that can be mishandled No fibers to age or stress or micro-crack No rods or disks that age No mirrors on which deposits can accumulate 20

22 Service & Maintenance Service and maintenance derives from Diode reliability Modularity of design: 500W blades field replaceable On board diagnostics: diode power monitoring and compensation Fine adjustments can be made by on board controller Larger adjustments possible by remote control via telemetry 24/7 service and maintenance to rely on local engineering & stocking Applications/Service centers to be located in key geographic locations Detroit: spares, applications lab Munich: spares, TBD Shanghai: spares, application lab Locations in Mexico and South America TBD Response time recognized as critical, with different levels of service to be available 21

23 Conclusion High power, high brightness laser sources are key to both the industrial and defense laser markets WBC direct diode lasers are the ultimate answer for Brightness Cost Effectiveness Compactness Efficiency Reliability TeraDiode multi-kw class high brightness direct diode lasers 22

24 Simply Brighter For white papers, go to: 23