Pelham, NH, United States
Pelham, NH, United States
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Elmer J.W.,Form Factor Inc. | Yaglioglu O.,Form Factor Inc. | Schaeffer R.D.,PhotoMachining, Inc. | Kardos G.,PhotoMachining, Inc. | Derkach O.,PhotoMachining, Inc.
Carbon | Year: 2012

We present a scalable approach for the fabrication of large-area arrays of carbon nanotube (CNT) structures using focused laser beams in the 0.05-10 W range. We show that CNT films can easily be micromachined into arrays of columns using a wide variety of commercially available pulsed lasers - Excimer, diode-pumped solid-state (DPSS), and CO 2 - operating at wavelengths from 248 nm to 9300 nm. We demonstrate that vertically aligned carbon nanotube (VACNT) arrays with pitches from 20 to 500 μm can be produced with aspect ratios greater than 20:1. Machining speeds up to 425 mm/s were demonstrated and trenches were produced from 10 to 200 μm wide depending on the laser method and beam size. The CO 2 laser had the largest beam diameter of 175 μm and produced the widest columns with the most taper. The remaining lasers, having beam diameters between 10 and 100 μm, produced smaller columns and finer pitch arrays. The VACNT arrays were shown to have high surface quality with no observable residue left behind, demonstrating focused laser micromachining as a readily available soft tooling means for direct manufacturing of VACNT devices. Laser micromachining methods are compared to evaluate the tradeoffs between quality and manufacturing costs. © 2012 Elsevier Ltd. All rights reserved.

Schaeffer R.D.,PhotoMachining, Inc.
Materials World | Year: 2011

The invention of highly focusable carbon dioxide lasers, UV lasers and ultra short pulse lasers has opened up new fields, allowing plastics to be processed with high speeds and very clean edge quality. Lasers can also be used to weld and mark plastics and other materials, but here the focus is on material removal such as cutting and drilling. Minimum achievable spot size is determined by a constant multiplied by the laser wavelength, focusability of the laser, focal length of the focusing lens, all divided by the clear aperture of the lens. Beam delivery is also important. Galvanometer beam delivery systems are much faster than using table motion alone, even when using high- speed linear tables or air bearing tables. In general, higher power and higher repetition rate lasers are also faster to a point, but usually it is difficult in most cases to use more than a few hundred kHz on target because the beam cannot be moved fast enough.

Carlton H.D.,Lawrence Livermore National Laboratory | Elmer J.W.,Lawrence Livermore National Laboratory | Freeman D.C.,Lawrence Livermore National Laboratory | Schaeffer R.D.,PhotoMachining, Inc. | And 2 more authors.
Journal of the European Ceramic Society | Year: 2015

A new method for notching ceramics was developed using a picosecond laser for fracture toughness testing of alumina samples. The test geometry incorporated a single-edge-V-notch that was notched using picosecond laser micromachining. This method has been used in the past for cutting ceramics, and is known to remove material with little to no thermal effect on the surrounding material matrix. This study showed that laser-assisted-machining for fracture toughness testing of ceramics was reliable, quick, and cost effective. In order to assess the laser notched single-edge-V-notch beam method, fracture toughness results were compared to results from other more traditional methods, specifically surface-crack in flexure and the chevron notch bend tests. The results showed that picosecond laser notching produced precise notches in post-failure measurements, and that the measured fracture toughness results showed improved consistency compared to traditional fracture toughness methods. © 2015 Elsevier Ltd.

Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase I | Award Amount: 99.82K | Year: 2010

This proposal uses commercially available products in a new and unique way to deliver multiple laser beams to the target simultaneously in order to increase processing efficiency. We will demonstrate the idea using mostly low power lasers available to us, but it can be scaled up using larger lasers. In addition, we will investigate methods of process monitoring to determine when the metal layer has been reached. We hope to demonstrate cycle times of less than 10 minutes per part and compare our data with other available methods. The method should address TCB thickness variations (0.005" - 0.020"), end point detection, no damage to underlying layers and zero recast. BENEFIT: Anticipated results will be applicable to not only removal of TBC coatings, but should also have application in other areas such as high speed hole drilling. The proposed Phase I work will determine the fundamental laser parameters required to controllably remove TBC coatings at high speed. This includes the optical set up and controlled feedback loops. Variations on the optical set up and choice of laser could be used in a variety of other areas, but in the aerospace/defense arena as well as the commercial manufacturing arena.

PhotoMachining, Inc. | Entity website

Inquiries about the following equipment can be made For a full listing, click this link Detailed Inventory List Microscopes, Magnification, Measurement Stereo Zoom Measuring Microscopes, Optical Systems, Electronics Eyepieces, Objectives, Optics Ellipsometers Inspection Illuminators, Light Tables Booms, Bases, Stands Measuring Devices and Standards Electronics and Electrical Oscilloscopes UPS, Line Conditioners Thermocouple and Temperature Measurement Electrical Supplies Power Supplies Function Generators Input/Output Devices Meters Cleanroom and Laboratory Equipment Clean Hoods, Ionizers, Dry Boxes, etc ...

Laser tools can make vias or orifices in virtually any material, from a thin plastic film to a ceramic wafer or CVD diamond coating. A tightly focused laser beam is an ideal tool, replacing hard tool bits in the manufacturing process ...

Motion Control / Part Handling A typical PhotoMachining laser micromachining tool has a 12"x12" or 24"x24" motion envelop. Encoders, down to 0 ...

Excimer Laser Systems UV photons can now be obtained from several other different laser sources, but excimer lasers, despite their drawbacks, still can do things no other lasers can do and, in some cases(a lot of small holes on closecenters), they can be economic since they use mask imaging instead of single point drilling. The resonator cavity configuration produces a beam ideal for near-field imaging and the high peak power of the laser beam permits ablation of the target material with little or no heat affected zone ...

Materials Most popular materials requiring laser processing are: Plastics, polymers Metals, including special alloys and refractory metals Ceramics, glass Gem stones, minerals, diamond (including CVD films) Whenever traditional technology fails, laser-assisted photomachining offers a cost effective and reliable solution. PhotoMachining demonstrates a fewreal lifeexamples of laserprocessed parts below on this page ...

Part Handling - Motion Control A number of parameters need to be considered for the motion control in a laser micromachining system. Specifications such as stage linearity, accuracy, repeatability, range of motion, number of linear and rotational axis, etc ...

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