Laser MicroJet Frequently Asked Questions

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1 Laser MicroJet Frequently Asked Questions Who is Synova? Synova is the inventor and patent owner of a new laser cutting technology (the Laser-Microjet) and provides its systems for a broad range of micromachining applications. Located in Switzerland, Synova SA designs, builds and sells its own machines, like the LCS and DCS series. Synova also works with partners to integrate the technology in non-synova base machines, like the MCS series built by Makino Japan Synova has presence in the USA through its Synova USA group, located in Fremont, CA. A second east coast location is planned to open in Q What is the relationship between Synova and Makino? From a Makino sales perspective, selling an MCS machine is equivalent to selling a 3 rd party machine. It would be sold as a Synova MCS machine. Synova has a manufacturing agreement with Makino Japan to build the MCS series. Synova also has in place a Sales and Service agreement with Makino USA. Our primary focus will be to sell the MCS series, but other machines (LCS series) can also be sold when there is a fit. What is a Laser MicroJet? Guiding light with water is not new. This was demonstrated in the mid-1800s. We can say that water was indeed the first optical fiber. More than 150 years later, Dr Richerzhagen applied the same principle to lasers. So, essentially, a Laser MicroJet is a water-guided laser used for machining purposes. The laser used is typically a commercial YAG green laser, operating at a wavelength of 532nm, with pulses in the nanoseconds range. Power ranges from 30W to 200W. optical fiber. Utilizing the difference in the refractive indices of air and water, the technology behind Laser MicroJet creates a laser beam that is completely reflected at the air-water interface. The laser is, therefore, entirely contained within the water jet as a parallel beam, similar in principle to an This lack of deviation is maintained through and beyond the work piece, facilitating the accurate cutting of thick, porous or layered materials, all with minimal thermal and structural distortion, leaving a fine cut edge. Its advantages outweigh both high-pressure water jet cutting and conventional laser cutting.

2 What is unique about this laser technology? Using water to guide the laser to a given workpiece has the following advantages: 1. Water Guides the Laser - The application becomes insensitive to the focal plane of the laser. A cylindrical laser beam is created resulting in perfectly parallel walls, tight kerf widths and enabling the user to cut thick or non-flat parts, without having to worry about being in focus. 2. Water Cools the Material - Heat is generated during laser ablation. When using a conventional laser system, a lot of the laser energy is absorbed by the surrounding material, creating an unwanted heat-affected zone. With an LMJ, much of the energy dissipates into the water and not in the material. There is very little heat-affected zone with the LMJ. Stress-induced conditions such as micro-cracking, thermal damage or defromation are greatly reduced. 3. Water Cleans the Surface When using a conventional laser, a portion of a laser-ablated material tends to redeposit and solidify at the surface of the part, creating an unwanted slag condition. With the LMJ, the water displaces that material before it solidifies, rendering a much cleaner entrance, wall and exit surfaces without particle deposition or burrs. How does it work? The laser combines with the water in a disk-like chamber and out comes a guided laser. A medium-pressure pump is used to generate a pressure between 50 to 500 bars. The nozzle orifice ranges in size. On MCS machines, we would typically use 60, 70 or 80 microns nozzles, but can be reduced to 50, 40 or 30 um, as a function of the integrated laser type. the water jacket. The water must be of the highest purity: deionized and stripped of all particle matter. The machine comes with its own water-purification system. Customers can connect to City Water. Helium is used as a stabilizing gas as an outer layer to

3 What are the technological advantages compared to a dry laser? The following table summarizes the major advantages of the Laser MicroJet : In summary, the Laser-Microjet allows a heat-damage and heat-distortion-free machining with a parallel laser beam that is unique in the world. Compared with Ultra-short pulse lasers that also claim to cut without heat, the LMJ is virtually not limited in the thickness; it generates a cut with 90 degree walls and it does not contaminate the surface. What is the advantage of the LMJ compared to EDM machining? The LMJ does not require electrical conductivity; therefore, the range of material is very wide. Ceramic coating or full ceramics can be cut as simply and as fast as metal. Hardness also plays no role; therefore diamond is also typical material for the LMJ. No starting hole is needed. No oxidation appears, the roughness is typically a factor of two or three better; the kerf width is significantly reduced; the flexibility in shape is also much larger. Cutting speed is similar or up to 5 times higher with LMJ depending on the thickness (max. 20 mm).

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5 What materials fit well with the LMJ? The following summarizes the materials that are a good fit, and those that are not: What are the typical markets served? As one can see from the list of materials above, applications spread out across a wide set of market segments. With Makino, we expect our sales to come from Aerospace, Energy (Industrial Gas Turbines), Defense, Medical, Automotive, Hard Material Tool Making, and General Metal Micro-Machining market segments.

6 What are typical applications? Sales Success is typically linked to applications where a high quality surface finish is required. Also, tight tolerances are typical. Machining of novel materials such as GE s Ceramic Matrix Composites (CMCs) are also an exceptional fit. Hard materials such as polycrystalline diamond, cubic boron nitride, silicon carbide and tungsten carbide are also a good fit because of the benefits of reducing the heat-affected zone. As in the case of hole-drilling, overall processes are frequently simplified. Drilling holes in a single step through the thermal barrier coating for example, instead of a 2-step process. Also, complex back-strike protection processes are eliminated. Moreover, combining the Laser MicroJet to a Makino EDM machines enables an optimum use of both technologies in a synergistic way. We are referring to this a Laser/EDM hybrid process. Interest has been extremely positive for an offering similar to the system being delivered to GE Power. Machining of a wide range of materials Any metal Most ceramics (zirconia, alumina, silicon carbide ) Superalloys with or without thermal-barrier coating Ceramic matrix-composites Main MCS applications: 1. Drilling of cooling holes in hot section components of IGTs, mainly turbines blades and vanes, even with applied thermal-barrier coating (extremely low recast in the metal, no cracks or delamination in the thermal-barrier coating, possibility to avoid any damage inside a drilled component thanks to a control of the water jet stability) Round holes Shaped holes (with diffuser; square, trapezoidal and inclined) 2. Cutting of ceramic-matrix composite parts Performance Capabilities in superalloys: 1. Aspect ratio of up to 1:20 (diameter: depth) 2. Diameter down to 0.3mm 3. Depth of up to 15mm 4. Average recast down to 1µm 5. Angle cutting possibilities down to Speed around 60s/hole

7 Who would be typical SST customers interested in this technology? As previously mentioned, potential customers are numerous. Examples of customers already engaged with either Synova or Makino include: GE Power, GE Aviation, GE healthcare, Pratt& Whitney, Rolls Royce, Siemens, Solar Turbines, Turbine Technologies, Stryker (Medical), Chardon Tools (Diamond Toolmaking), BAE Systems, Lockheed Martin, Raytheon, TE Connectivity.

8 Which machines will be selling? Our primary focus should be on selling the MCS Series. Synova is also introducing its smaller footprint LCS-50 to the North American market. This compact machine is well suited to small pieces (50mm x 50mm) such as diamond tools and precision components in the watchmaking and medical industry, as well as in precision engineering. - Accuracy +/- 3µm - HMI on 15 inch touch screen - New photos:

9 What is the price of a system? The price depends on the application to some extent, and how much engineering is required to develop the process. A 5-axis MCS500 system would be in the 1.3M to 1.4M A 3-axis MCS300 system would be in the 800K range. A 5-axis LCS 50 would carry a price tag of around 550K to 650K. Is this a catalog item? No, typical Laser MicroJet applications require a thorough applications review, and samples are frequently processed to demonstrate the process. Systems are to be quoted on a case-by-case basis. Makino has a demo MCS 500 at Mason. A LCS 50 will be available for demonstrations and sample processing in the coming Micro-Machining Center in New Jersey. What is the lead time on a system? Lead Times vary but 20 to 26 weeks ARO is typical. What is the installed base of MCS machines? There are 2 MCS systems presently installed at GE Power in Greenville. More systems are installed in Europe and Japan. Additional systems are expected for both GE Power and GE Aviation this year. We expect a significant increase in 2017.