fiber lasers for medical applications · rtbl repeatable process high accuracy high reliability...
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AILU – PHOTONEX 0816th October 2008
Fiber Lasers for Fiber Lasers for Medical ApplicationsMedical Applications
Dr Jack Gabzdyld l d
Not to be distributed without prior consent of SPI Lasers plc
Product Line Manager – Pulsed Lasers
GeneralGeneral Advantages of Fibre LasersAdvantages of Fibre Lasers
Beam Quality & StabilityDiffraction-limited beam Small spot size (<10um possible)N i ti d ift th l l i blNo pointing drift nor thermal lensing problemsFlexible beam delivery
All Fiber Integrated: No free space optics to adjust / tune Zero-maintenance solid-state systemCompact and easy to integrate
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Operational BenefitsLow-power consumption (wall-plug efficiency)No gases requiredNo consumable itemsFewer support specialists
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R4 High Power LaserR4 High Power Laser
25-200W Air Cooled
Features
100-400W Water Cooled
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- CW or Modulated to 100 kHz (modulated pulses <5µs to CW)
- TEM00 (M² <1.1), <BPP 0.37 mm.mrad
- Central Emission Wavelength: 1070 ± 10nm
-High stability laser (typically <±0.5% output power variation)
G3 Pulsed laser rangeG3 Pulsed laser range
Features of 10 & 20 W/RM, 12 & 20W/HS and 30W/HM
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Features- Up to 500 kHz pulse repetition frequency
- Pulsed and CW operation- Pulse width variable (across 25 pre-set waveforms)
- Peak Emission Wavelength: 1064 ± 5 nm
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Compact Laser ModuleCompact Laser Module1090/1550/1565nm
CLM 1090nm CLM 1550/1565nm
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CLM –1090nm
Features-CW or Modulated to 50kHz
(modulated pulses 10µs to CW)- TEM00 (M² <1.1), BPP 0.38 mm.mrad
CLM –1550/1565nm
Features- Up to 20W optical output power
- Diffraction limited to beam quality (M2<1.1)
Why a Fibre Laser ? Why a Fibre Laser ?
Key differentiators vs YAG/CO2Size
Common 5U 19” Rack format
Performance Power Stability & Linearity Modulation & Control RangeBeam Quality
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Total Cost of OwnershipNo scheduled maintenance intervalEnergy Efficiency
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Performance : Beam QualityPerformance : Beam Quality
Application: Ceramic scribingFibre Laser λ=1.07um, M2<1.1
M2 < 1.1
200W Fibre Laser
CO2 Laser λ=10.6um, M2~1.3
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400W CO2 Laser
Total cost of ownershipTotal cost of ownership
Fibre Lasers vs YAG LasersFibre Laser Lamp pumped YAG
Diode Pumped YAG
Scheduled Maintenance Interval
None 500-1000 Hours ( Lamp Pumped)10,000 Hours ( Diode Pumped ) Optical path requires frequent adjustmentRegular replacement of flashlampsPeriodic maintenance/ replacement of diode packs Diode pack maintenanceCleaning replacement and alignments of lenses and mirrors
C bl i $ 00 200 h
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Consumable items None Lamps : $100-200 each Diode Packs : $5000-12000 each (Note: average costs)
Power Consumption Single phase 15-20% WPE
Single/3Phase 2-10% WPE
Chiller Not required for < 200W Cost $4000-$8000Replacement period ~ 24months
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Output power stability Output power stability
200W Laser over full operating temperature range 10-40˚C
314539-SP-200C-0004 Active Cycle Started 11 March 2008 18:29:25 Ended 12 March 2008 01:59:25
195
200
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Pow
er (W
)
15
20
25
30
35
40
45
Tem
p (°
C)
Pow er_(W) Set_Temp Act_Temp Delta Power = 0.40W (± 0.1 %)
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0 1 2 3 4 5 6 7
Time (hrs)
P
5
10
15 T
Pulse to pulse stabilityPulse to pulse stability
Pulse Energy Distribution for 10Hz, 50msec pulses at 100W
708090
010203040506070
4.81 4.82 4.83 4.85 4.86 4.87 4.89 4.90 4.91 4.93
Pulse Energy (mJ)
No.
Pul
ses
Min 4.832J
Max 4.882J
Sigma 0.007J
Avg 4.857J
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68.26% of all pulses are within ±0.007J of 4.857J (0.15%)95.46% of all pulses are within ±0.014J of 4.857J (0.31%)99.73% of all pulses are within ±0.021J of 4.857J (0.46%)
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High modulation rateHigh modulation rate
200W Laser at 100kHz, 50% Duty cycle
Pulse shape of 200W laser at frequency of 100kHz and 50% duty cycle
0.10
0.15
0.20
0.25
0.30
0.35
Sign
al (a
rb)
Trigger
Signal
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-0.05
0.00
0.05
0 2 4 6 8 10 12 14 16 18 20
Time (us)
Medical ApplicationsMedical Applications
Materials processingCuttingWeldingRapid PrototypingMarking
TherapeuticM di l A th ti
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Medical Aesthetics
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Fine tube CuttingFine tube Cutting
Wide range of tubes and needles used in medical applicationsmedical applicationsPredominantly stainless steel but can be other metalsFine features required
h
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High part accuracyNo burrs
Micromachining Micromachining Thin metal sheet and tube cuttingThin metal sheet and tube cutting
High beam quality allows very fine kerf as lowas 10um widths to be achieved for thin materials Cutting speeds with conventional solid state lasers are limited
Cutting highly detailed Coronary Stents
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Cutting speeds with conventional solid state lasers are limited by repetition rates of a few kHz The direct modulation capability up to 100kHz of SPI’s CW-M fibre lasers allows high speed cutting process developmentProductivity improvements >5x in cutting speeds have been demonstrated by fibre lasers in these applications
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Growing use of laser welding in Growing use of laser welding in medical device manufacturemedical device manufacture
Laser welding providesHigh quality jointsR t bl Repeatable processHigh accuracyHigh reliabilityProcess that is in controlAbility to weld small and thin partsAbility to weld wide range of metallic materials
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Ability to weld wide range of metallic materialsWelding of dissimilar materials
Traditionally Nd:YAG systems were used but now the Fibre laser is becoming the laser of choice
Comparable Nd:YAG weldComparable Nd:YAG weld
C l l thCan clearly see the overlapping spot welds in this pulsed seam weldTypical pulsed YAG weld in stainless steel
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Micro Welding of tubesMicro Welding of tubes
Material: 304 SS Laser Power: 90 60 30 W
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Material: 304 SS
Speed: 3.5m/min (140”/min)
Focal length: 100 mm
Cover gas: Argon
Laser Power: 90, 60, 30 W
Tube diameter: 1.5 mm
Wall thickness: 0.4 mm
Bead on plate, fully penetrating
Welding Brachytherapy seedsWelding Brachytherapy seeds
35W power, 3s welding durationTube length used for rounded end: ~1.2 mm
Welding Brachytherapy SeedsSPI Lasers’ 100W Fiber Laser
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Material – TitaniumShield gas - Argon
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Welding guide wire components Welding guide wire components
MaterialStainless Steel
Material thicknessMaterial thickness2.2 mm
Laser Power60 W
Cover gasArgon
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Focal length lens100 mm
Weld speed time20 ms
Thin sheet weldingThin sheet welding
Material: Stainless SteelThi k (b h Thickness (both sheets): 25 mmPower: 30 WSpot diameter: 50 µmWeld time: 3 ms
200 μm
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Weld time: 3 msWeld method: Trepanning
200 μm
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Butt welding of fine wiresButt welding of fine wires
Material: TungstenDiameter: 75 μmPower: 20 WSpot size: 50 μmPulse length: 1 msCover gas: Argon
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Butt welding of fine wiresButt welding of fine wires
Material: NitinolDiameter: 0.26 mmPower: 45 WOptics: 120 mm focusing lens, no beam expanderSpot size: 60 μm
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μPulse length: 20 msCover gas: Argon
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Wire BallingWire Balling
In medical applications numerous wires are numerous wires are used for insertion..No sharp edges can be toleratedHitting the end of cut
i i h l i 0.33mm diameter
l ti i lt d
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wire with laser gives round ball end with no sharp edges
platinum wire meltedSPI 70W Air Cooled laser
Endoscope weldingEndoscope welding
Material: SS 1.4301Power: 50 WWeld speed: 50 mm/secWeld speed: 50 mm/secPart Diameter: 1.4 mmWall thickness: 0.1 mmBeam radius: 30 µm
Not to be distributed without prior consent of SPI Lasers plcCourtesy of Fraunhofer Institute for Laser Technology
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Rapid PrototypingRapid Prototyping
x-y Scanner Laser
Laser BeamLevelling System
Window
Metal PowderPart Part
Laser Beam
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Retractable Platform
Powder
Courtesy of MCP-HEK
Example Example ““MainstreamMainstream”” Application Application for Generative Microprocessing / Manufacturingfor Generative Microprocessing / Manufacturing
Dental Caps!Dental Caps!
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Images courtesy of MCP-HEK
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Plastic WeldingPlastic Welding
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Plastic Welding of medical equipmentExample: Catheter kit and syringe welding
Fiber laser can give greater precision and finer spot size than DL
Medical markingMedical marking
Diverse number of applications
D t t iData matrixGraduationsPart numbersMarketing
Wide range of materialsS ifi i t
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Specific requirementsOperating instruments need to go through sterilisation
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Medical AestheticsMedical Aesthetics
Wrinkle removalC t l d lCompact laser module1550nm
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SPI’s Application facilitySPI’s Application facility
SPI has a dedicated technical facility in Santa Clara to support customer applications
Our staff have over 50 years of combined laser materials processing experienceCustomer samples are processed FOC on a case basis for a “proof of principle” More detailed process development is undertaken on a commercial basis
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SPI offer a 30-day free evaluation laserOur on-site equipment includes commercially available systems
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SummarySummary
Fiber lasers are an alternative source for many medical related device manufacturing applicationsapplicationsFiber lasers
Low costNo maintenanceCompactHigh quality
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Helping medical industry to:Reduce costsImprove quality
Thank You – Questions?
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