Novel Green Lasers Revolutionize Cutting of Polycrystalline Diamonds

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1 Novel Green Lasers Revolutionize Cutting of Polycrystalline Diamonds Lasers in Action Forum, LASYS 2018, Stuttgart Christian Hahn, InnoLas Photonics GmbH,

2 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 2 LASYS 2018, Stuttgart

3 Company Introduction InnoLas Photonics GmbH Justus-von-Liebig-Ring 8 D Krailling, Germany Fon: Fax : Google Maps 3 LASYS 2018, Stuttgart

4 Product Overview Q-Switched DPSS Lasers All-in-One Marker FEMTO All Fiber Lasers Direct Diode Lasers High Energy Lasers 4 LASYS 2018, Stuttgart

5 Markets Marking, Trimming, Engraving Structuring, Drilling, Cutting, Additive Manufacturing ID Cards / Homeland Security 5 LASYS 2018, Stuttgart

6 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 6 LASYS 2018, Stuttgart

7 The Evolution of Synthetic Diamond 1879 / 1893 Hannay & Moissan: First attempt to synthesize diamonds 1954, Tracy Hall: The GE Diamond Project - First reproducible grow of synthetic diamond 2018, New York Times: A Battle Over Diamonds Artificial diamonds reach jewelry stores Pictures: Bain News Service, Wikipedia, Shutterstock 7 LASYS 2018, Stuttgart

8 Why Synthetic Diamond? Environmental Footprint Mined Diamond Grown Diamond Ratio Emissions a. Carbon Oxides b. Nitrous Oxides c. Sulphur Oxides 57 kg/ct 42 kg/ct 14 kg/ct 28 mg/ct 0.09 mg/ct 0.00 mg/ct Energy Usage MJ/ct MJ/ct 2.1 : billion : 1 (in total) Land Excavated 91 m²/ct m²/ct 1282 : 1 Disposed Mineral Waste 2.63 t/ct 0.6 kg/ct 4383 : 1 Water Usage 480 l/ct 70 l/ct 6.9 :1 Source: Frost & Sullivan 8 LASYS 2018, Stuttgart

9 Why Synthetic Diamond? Diamond Demand and Supply in Mio ct Rough Diamond Demand Mio ct Mined Diamond Supply in Mio ct Supply gap of 278 Mio ct (55.6 t) in 2050! Source: Frost & Sullivan 9 LASYS 2018, Stuttgart

10 Synthetic Diamond Market Evolution 200 Synthetic Diamond Production in Mio Ct for Gem Applications for Non-Gem Applications Estimated CAGR of 7.4% in the next five years , ,9 1, Source: IGDA 10 LASYS 2018, Stuttgart

11 Global Synthetic Diamond Market Market Share (%) by Region Asia-Pacific North America Middle-East & Africa Europe ROW Source: Research Nester 11 LASYS 2018, Stuttgart

12 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 12 LASYS 2018, Stuttgart

13 Diamond Manufacturing Technologies High Pressure High Temperature (HPHT) Chemical Vapor Deposition (CVD) > C < C Bulk diamond, grit, powder & melee Tooling, Gems Large area diamond disks, bulk diamonds Gems, Optics, Electronics, Tooling The Carbon Graph Materialscientist, Wikipedia Steve Jurvertson, Wikipedia Roslan Md Nor et Al., Diamond: Synthesis, Characterisation and Applications 13 LASYS 2018, Stuttgart

14 Industrial Diamond Tools Brazed PDC Metal-bonded Plated Resin-bonded Ceramic-bonded PCD Pictures: ILP, Shutterstock 14 LASYS 2018, Stuttgart

15 PCD Tool Inserts PCD Carrier Metall WC Substrate 15 LASYS 2018, Stuttgart

16 From Diamond Grit to PCD What is PCD and how is it made? Polycrystalline Diamond (PCD) is a diamond grit or sand that has been fused together under high temperature and high pressure in the presence of a catalytic metal and sintered to a hard metal carrier (WC). PCD WC D t T Wafer Diameter (D) PCD Thickness (t) Grain Size Overall Thickness (T) 38.0mm 500µm 2 / 5 / 10 / 25µm 1.6 /2.0 / 3.2mm 45.0mm 500µm 2 / 5 / 10 / 25µm 1.6 /2.0 / 3.2mm 51.0mm 500µm 2 / 5 / 10 / 25µm 1.6 /2.0 / 3.2mm 16 LASYS 2018, Stuttgart

17 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 17 LASYS 2018, Stuttgart

18 PCD Cutting & Shaping Wafer Separation PCD piece Raw cutting insert with PCD Final cutting insert with PCD Cutting / shaping of edges 18 LASYS 2018, Stuttgart

19 Common PCD Cutting Technologies Technology Pros Cons Abrasive Grinding Low initial costs Good edge quality Slow Electrical Discharge Machining (EDM) Faster Free-form cut Good precission (<30µm) Tooling costs (wear of diamond tooling) Unflexible Limited inner edge radii Microchipping on edge Doesn t work on coarse PCD grit Poor edge quality Unflexible Limited inner edge radii Electrical Discharge Grinding (EDG) Good edge quality Intermediate speed Tooling costs Unflexible Limited inner edge radii Microchipping on edge Doesn t work on coarse PCD grit 19 LASYS 2018, Stuttgart

20 PCD Laser Cutting Technology Pros Cons Laser Cutting Fast High accuracy & precision (< 2.5µm) Sharp edges No Chipping Arbitrary free-form cut Chip breaker possible No tooling costs Higher initial machine costs than grinding, but comparable with EDM/EDG Laser Cut 20 LASYS 2018, Stuttgart

21 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 21 LASYS 2018, Stuttgart

22 PCD Laser Cutting & Shaping BLIZZ 532nm DPSS Laser Operating Parameters: 40W, 40kHz, 1.0mJ, 20ns 50kW Peak Power 22 LASYS 2018, Stuttgart

23 PCD Laser Cutting InnoLas Photonics Applications Lab Setup: Laser: BLIZZ V, 40W Green Galvo: 10mm aperture F-Theta: f = 100mm Material: PCD on WC carrier, thickness 1.6mm 23 LASYS 2018, Stuttgart

24 PCD Laser Cutting d PCD = 0.5mm d WC = 1.1mm cutting speed: up to 3.6mm/min 24 LASYS 2018, Stuttgart

25 PCD Laser Cutting & Shaping 2.5µm edge roughness Up to 3.6mm/min cut speed Free-form cutting Cut thru PCD and WC carrier 5x 10x 20x 40x 2.5µm edge roughness 25 LASYS 2018, Stuttgart

26 Laser Cutting & Shaping Advantages Grinding / EDM Grinding wheel or EDM wire diameter limits the cutting edge inner radius of the PCD Laser Cut Sharp edges in any angle Arbitrary free-form cut possible Laser spot size is the only limit (< 10 µm) 26 LASYS 2018, Stuttgart

27 Laser Generated Chip Breakers PCD Removal on Cutting Edge and Surface Generation of arbitrary 3D structures Novell chip breaker designs possible Laser tuning of cutting edge Laser spot size is the only limit! Hoffmann Group 27 LASYS 2018, Stuttgart

28 Marking of Carrier Metal Temperature and wear resistant marking on: Tungsten Carbide Molybdenum Densalloy Mallory Titanium Carbide Vanadium Carbide 28 LASYS 2018, Stuttgart

29 Overview Company Introduction Synthetic Diamond Market Diamonds for Tooling PCD Cutting Technologies Laser Cutting & Shaping of PCD Summary 29 LASYS 2018, Stuttgart

30 Summary High power 532nm, short pulsewidth BLIZZ lasers enable Fast processing speeds up to 3.6mm/min Clean cut and shaping of PCD Clean cut and shaping of WC Arbitrary cutting edge designs High-tech chip breaker designs No tooling costs Visit us on Booth E59 in Hall 4! Low cost of ownership 30 LASYS 2018, Stuttgart

31 Thank you!