Lasers-based Manufacturing

Applications
Εφαρμογές Κατασκευαστικής με Βάση
το Λέιζερ
#1
Course Details and Application Examples

Claus G. Rebholz, Ph.D.

LASER TECHNOLOGY – Fall 2020

Today’s Program
• Course Details & Introdcuction

• Laser Roots & History

• Examples Laser Applications

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 Course Details
& Introduction

MMK 442 - Course Purpose &

Objectives
Course Purpose & Objectives:
Provide an overview of new and evolving manufacturing
applications where laser processing plays a significant
enabling role or relating to new production techniques.

Στόχοι Μαθήματος:
Παρέχεται μια γενική εικόνα των νέων και εξελισσόμενων
εφαρμογών κατασκευαστικής, όπου η επεξεργασία με λέιζερ
παίζει σημαντικό ρόλο ή σχετίζεται με τις νέες τεχνικές
παραγωγής.

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MMK 442 - Learning Outcomes
Learning Outcomes:
1. Familiarity with different laser types and their general
applications
2. Recognition of production processes offered by lasers
3. Understanding of what applications are emerging in
lasers, processes and materials.
4. Knowledge of additive manufacturing processes
5. Acquaintance with materials joining, surface
processing/modifications and micro-manufacturing
processes
6. Familiarity with methods above in the laboratory and
practice

MMK 442 - Learning Outcomes

Μαθησιακά Αποτελέσματα:
1. Εξοικείωση με διαφορετικούς τύπους λέιζερ και τις
γενικές εφαρμογές τους
2. Αναγνώριση των διαδικασιών παραγωγής που
προσφέρονται από τα λέιζερ
3. Κατανόηση των εφαρμογών που αναδύονται σε λέιζερ,
διαδικασίες και υλικά.
4. Γνώση των διαδικασιών πρόσθετης κατασκευαστικής
5. Γνωριμία με την ένωση υλικών, επεξεργασία/τροποποίηση
επιφανειών και διαδικασίες μικρο-κατασκευαστικής.
6. Εξοικείωση με τις παραπάνω μεθόδους στο εργαστήριο
και πρακτικά

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 MMK 442 – Course Contents
Lasers are part of everyday tasks, such as reading
grocery prices and printing or copying paper
documents. This course emphasises on the innovative use
of lasers in manufacturing and material processing. Topics
covered include: Laser background and general
applications; Additive manufacturing (selective laser
melting and sintering, manufacturing of multi-materials);
Laser joining (welding of metals and plastics); Laser
surface processing and modifications (texturing and
coating deposition, and general surface processing and
modification applications); Micro-manufacturing (laser
cutting, drilling and welding for automotive, medical and
other applications). The lecture material will be
reinforced by laboratory sessions and problem sets.

MMK 442 – Course Contents

Τα λέιζερ αποτελούν μέρος των καθημερινών εργασιών, όπως η
ανάγνωση των τιμών των τροφίμων και η εκτύπωση ή η
αντιγραφή εγγράφων σε χαρτί. Αυτό το μάθημα δίνει έμφαση
στην καινοτόμο χρήση των λέιζερ στην κατασκευαστική και την
επεξεργασία υλικών. Τα θέματα που καλύπτονται
περιλαμβάνουν: υπόβαθρο του Laser και γενικές εφαρμογές,
πρόσθετη κατασκευαστική (επιλεκτική τήξη και σύντηξη με
λέιζερ, κατασκευαστική πολλαπλών υλικών). Σύνδεση με λέιζερ
(συγκόλληση μετάλλων και πλαστικών). Επεξεργασία και
τροποποιήσεις επιφανειών με λέιζερ (εναπόθεση υφής και
επικάλυψης, και γενικές εφαρμογές επεξεργασίας και
τροποποίησης επιφανειών). Μικρο-κατασκευαστική (κοπή με
λέιζερ, διάτρηση και συγκόλληση για αυτοκινητιστικές, ιατρικές
και άλλες εφαρμογές). Το υλικό διαλέξεων θα ενισχυθεί με
εργαστηριακές συνεδρίες και σύνολα προβλημάτων.

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 MMK 442 - Course Overview
• Course length: 13 weeks
• 26 lectures split in
– ~18 lectures (Mo./Th., 16:30-18:00, ΧΩΔ01-002 and
We., 9:00-10:00, ΧΩΔ01-102) and
– ~8 lab demonstrations/lectures*
• Evaluation
- Lab reports/project (30%)
– Mid term Exam 14/11 (30%) and
– Final Exam (40%)

* dependent on available equipment/lab setup and the COVID-19 situation.

MMK 442 - Planed Labs*

• Laser Scanning & Rapid Prototyping
• Laser Cutting & Marking (Dept. of Architecture)
• Laser Micro-Welding
• LAwave (Laser Accoustic Surface Waves for
elastic modulus, density and thickness evaluation)…

• Pulsed Laser Deposition Lab Visit

• Laboratory of Ultrafast Science Visit (Dept. of
Physics)

* depending on available equipment/lab setup and the COVID-19 situation.

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 Labs (1)
3D Laser Scanning + Rapid Prototyping

Labs (2)
Laser Marking/Cutting
http://ucy.ac.cy/arch/en/ (Dept. of Architecture)

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 Labs (3)
Laser Micro-Welding

Starweld Manual
Performance (SWMP) from
rofin

Labs (4)
LAwave (Laser Accoustic Surface Waves)

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 Labs (5)
Pulsed Laser Deposition Laboratory Visit
http://www.ucy.ac.cy/complexfunctionalmaterialslab/en/

Labs (6)
Laboratory of Ultrafast Science Visit
http://www.ultrafast.ucy.ac.cy/ (Dept. of Physics)

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 MMK 442 - Planed Company
Visits*
• Laser Signs
• Andreou Brothers
• …

* depending on students’ interest and the COVID-19 situation.

Company Visits (1)

Laser Signs
https://www.lasersignscy.com/

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 Company Visits (2)
Andreou Brothers
http://andreou.com/en/group/divisions/andreoulaser/

https://my-grill.eu/cy/el/

Why are you here?

• Why did you choose the ‘Laser-

based Manufacturing Applications’
course?

• What will you do/are your plans

after your academic training?

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 Under- & Postgraduate
Funding Opportunities
• UCY-MME
http://ucy.ac.cy/mme/en/postgraduate/scholarships-
employment
• Υπουργείου Ενέργειας, Εμπορίου και Βιομηχανίας
http://www.mcit.gov.cy (see next slides)
• ERASMUS+ https://ec.europa.eu/programmes/erasmus-
plus/node_en
• IAESTE (International Association for the Exchange of
Students for Technical Experience) https://iaeste.org/
• …

Δοκιμή και Λάθος

“Η μεγαλοφυΐα είναι 1%
έμπνευση και 99%
ιδρώτας … ποτέ δεν
έκανα τίποτα άξιο τυχαία,
αλλά ούτε οποιεσδήποτε
από τις εφευρέσεις μου
δημιουργήθηκαν τυχαία.
Δημιουργήθηκαν από την
εργασία”

(Thomas Edison)

from Matthews, Andrew. Being Happy,

Media Masters, Singapore, 1988, p.91

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 Contact Details

Claus Rebholz
Tel: (+357) 2289 2282 - Mobile: (+357)
99105125
claus@ucy.ac.cy

Skype: rebholzc

• Associate Professor, MME UCY, since 11/2004

• Group Leader & Manager Laser Materials
Processing, Robert Bosch GmbH,
Stuttgart/Germany, 2001-2004
• R&D Executive Management Trainee in Advanced
Materials & Surface Engineering, Robert Bosch
GmbH, Germany/Japan/USA, 1998-2001
• MSc and PhD in Engineering Design and
Manufacture, Uni. of Hull/UK, 1995 and 2000
• BSc in Materials & Surface Engineering,
University of Applied Sciences,
Furtwangen/Germany, 1993

• Research Philosophy
Basic,inter/multi-disciplinary research,inspired
by industrial questions/problems

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 Laser Technology @ Bosch
2001 - 2004: Department of Engineering Processes and Technology

Research & Laser Production (e.g.

Development Technology EV14: 350.000
parts/day
worldwide)
- Mainly application specific process development,
consulting and support of product development and
manufacturing word-wide within the Robert Bosch group
- Equipment Design, Built-up & Service
- `No publishing policy´

Laser Applications @ Bosch

Innovation Principle Technology Use for Customer

Laser precision • Drilling of injection • Realisation of new hole

drilling components with pos. and geometries and small
neg. conicities diameters (60 µm)
• Simultaneous Engineering
(SE) team with Bosch R&D
departments and production
sites in Germany & France
• Components for gasoline • New laser beam
Laser welding
and diesel high pressure guidance/ shaping
metals
injection concepts resulting in
• Process module additional applications
development • Cost reduction potential
using standard modules

• Soft soldering process with • Bonding process with low

Laser soldering
additional soldering wire thermal stress
• Monitoring/control of process • Cost reduction potential
parameters (` temperature using standard modules
controlled laser soldering
process´)
• Process module
development

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 Laser Applications @ Bosch
Innovation Principle Technology Use for Customer
Laser penetration • Welding of thermoplastics • Simplification/replacemen
welding of • Overlap welding: upper layer of complex assembly
plastics transparent for laser beam, processes
lower layer absorbs laser • Product development
beam process support through
test sample production

• Standard module development • Cost reduction potential

Laser welding for 2D applications
• Cycle time reduction
module (LSM) • application of linear potential
drives/stages
• No work-piece movement
• further development of PC
based control concepts

ProFi-project
• Remote welding machine with • Potential for new
big workplace area applications
• fast processing with scanner • Flexible programming
• 3D-flexibility through disk • No work-piece movement
laser
• intelligent work piece
detection and seam tracking
• integrated process control

Laser Roots &

History

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 Laser Roots & History

1905 – idea
by Einstein

1957 – patent 1961 – ruby

by Gould laser by Maiman

Principle of Laser
Light Amplification by Stimulated
Emission of Radiation

Resonator

Laser Active Medium

Laser Light

Rear mirror Front mirror

R=100% R<100%
Pump Source

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 Examples Laser
Applications

Laser Applications
Manufacturing Medicine
Measurement Technology Laser surgery,
Technology Additive manufacturing, Retinal detachment,
Cutting, drilling, welding, Tumor treatment, …
Surface inspection,
soldering, hardening,
length & angle
marking, coating, …
measurements, …
Laser Technology

Education, Communication
Entertainment Optical fibres,
CDs, laser displays, … Laser printer, -scanner,…

Commerce
Bar coding, …

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 Lasers & Entertainment

Lasers & Manufacturing –

The Universal Tools
Applications
• Additive Manufacturing
• Fine Cutting
• Precision Drilling
• Precision Spot & Seam Welding
• Marking
• Surface Treatment
•…

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Additive Manufacturing

Additive Manufacturing

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 Cutting Applications

Medical Device Industry

Angioplasty stents
Needles, endoscopes
Saw blades, knifes

Electronics
Solder screen stentcils
Si- and GaAs wafer

Automotive Industry
Powertrain parts
Hydraulic slide valves
2D and 3D car body components

Courtesy of LASAG

Laser Drilling
High Speed Drilling Precision Drilling
High pressure diesel injection Precision holes for injection
filters systems
∅ 30-800 µm ∅ 60-200 µm
± 10 µm Roundness < 2 µm
Up to 500 holes/second Few seconds/hole

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 Laser Precision Drilling

Schematic of
drilling process

Drilling of
injection
nozzle
Diesel injection nozzle,
and spray pattern of
14 hole nozzle

Laser Welding of Plastics

Laserstrahl
•Overlap welding of
thermoplastics: upper layer
transparent for laser beam,
IR-transparent
lower layer absorbs laser
beam IR-absorbierend
Wärmeeinflusszone
•Simplification/replacement
of complex assembly
processes

Fuel filter

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Seam Welding Applications

Medical Device Industry

Implants
Surgery tools

Electronics
seam weld Hybrid casings
Batteries, Sensors
Transformer packages

Automotive Industry
Airbag ignitors
Sensors

Courtesy of LASAG

Spot Welding Applications

Medical Device Industry
Implants
Surgery tools

Electronics
Connectors, relais, sensors
Lead frames, TV tubes
Optoelectronical components

Automotive Industry
Sensors
Fuel injectors

Other industries
Micro parts of watches

Courtesy of LASAG

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 Laser Welded Rail
Laser Welded Rail
Replacement of forged rail
modular construction
high dynamic pressure load (>1600bar)
Forged & Laser Welded Rail
realisation: stitch-welding (Nd:YAG)
seam welding with filler wire (CO2, high quality)

Seam welding and cross-section of

high pressure connection New Machine Concept

Laser Surface Texturing

– Tribologically effective
microstructures for wear reduction
– Dia. dots: 5-50 μm, depth: app. 10 μm
Reduction of
fretting

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 Lasers & Medicine –
Laser Cosmetic Surgery

Lasers & Medicine – Tattoo

Removal

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 Laser Eye Surgery

Selected Literature
– Laser Material Processing
William M. Steen and Kenneth Watkins
© 2010 (2003) Springer, ISBN: 1852336986

– A large list of text books to lasers and their

applications can be, for example, found at:
http://www.lasers.org.uk/Resources/books.htm

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THE END

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