Abstract: A system and method is disclosed for detecting anomalies in an additively manufactured part. An energy source generates a signal forming an optical beam for creating a melt pool in a layer of feedstock material being selectively fused to make a part in an additive manufacturing operation. A sensor is configured to receive a signal reflected from the melt pool. The reflected signal forms a thermal signal indicative of a temperature of the feedstock material at a known location on a layer of the feedstock material while the feedstock material is being fused at the known location. A controller receives and analyzes data relating to the received signal to determine if an anomaly exists at the known location.

Abstract: The present disclosure relates to a laser system for processing a material. The system may make use of a laser configured to intermittently generate a first laser pulse of a first duration and a first average power, at a spot on a surface of the material being processed, and a second laser pulse having a second duration and a second peak power. The second duration may be shorter than the first duration by a factor of at least 100, and directed at the spot. The second laser pulse is generated after the first laser pulse is generated. The first laser pulse is used to heat the spot on the surface of the material, while the second laser pulse induces a melt motion and material ejection of molten material from the melt pool.

Abstract: The present disclosure relates to an apparatus for modifying a curvature of a thin plate optic using controlled heat and densification of portions of the optic. In one embodiment the system has a support structure for supporting the optic about a perimeter thereof, a laser configured to generate a beam having a predetermined energy, and the beam being directed at one surface of the optic. The beam heats and densifies portions of the optic to create a force on the optic. The force induces a stress produces a controlled deformation of the optic. The controlled deformation at least one of modifies a curvature of, or corrects a defect in, the optic.

Abstract: A system and method is disclosed for detecting anomalies in an additively manufactured part. An energy source generates a signal forming an optical beam for creating a melt pool in a layer of feedstock material being selectively fused to make a part in an additive manufacturing operation. A sensor is configured to receive a signal reflected from the melt pool. The reflected signal forms a thermal signal indicative of a temperature of the feedstock material at a known location on a layer of the feedstock material while the feedstock material is being fused at the known location. A controller receives and analyzes data relating to the received signal to determine if an anomaly exists at the known location.

Abstract: The present disclosure relates to a laser-based system and method for providing efficient melt removal of material from a surface of a material sample being acted on in a laser machining operation. In one implementation the system may make use of a continuous wave (CW) laser for generating a laser beam directed at a spot on the surface of the material sample. The CW laser may be configured to be modulated at a predetermined frequency such that the laser beam excites and amplifies surface capillary waves on the surface of the sample up to a melt ejection point, which ejects molten material from the spot being acted on by the laser beam, to more rapidly facilitate material removal from the spot.

Abstract: The present disclosure relates to a laser system for processing a material. The system may make use of a laser configured to intermittently generate a first laser pulse of a first duration and a first average power, at a spot on a surface of the material being processed, and a second laser pulse having a second duration and a second peak power. The second duration may be shorter than the first duration by a factor of at least 100, and directed at the spot. The second laser pulse is generated after the first laser pulse is generated. The first laser pulse is used to heat the spot on the surface of the material, while the second laser pulse induces a melt motion and material ejection of molten material from the melt pool.

Abstract: Techniques for removing material from a substrate are provided. A laser beam is focused at a distance from the surface to be treated. A gas is provided at the focus point. The gas is dissociated using the laser energy to generate gas plasma. The substrate is then brought in contact with the gas plasma to enable material removal.

Abstract: A method of forming a surface feature extending into a sample includes providing a laser operable to emit an output beam and modulating the output beam to form a pulse train having a plurality of pulses. The method also includes a) directing the pulse train along an optical path intersecting an exposed portion of the sample at a position i and b) focusing a first portion of the plurality of pulses to impinge on the sample at the position i. Each of the plurality of pulses is characterized by a spot size at the sample. The method further includes c) ablating at least a portion of the sample at the position i to form a portion of the surface feature and d) incrementing counter i. The method includes e) repeating steps a) through d) to form the surface feature. The sample is free of a rim surrounding the surface feature.

Abstract: A method of forming a surface feature extending into a sample includes providing a laser operable to emit an output beam and modulating the output beam to form a pulse train having a plurality of pulses. The method also includes a) directing the pulse train along an optical path intersecting an exposed portion of the sample at a position i and b) focusing a first portion of the plurality of pulses to impinge on the sample at the position i. Each of the plurality of pulses is characterized by a spot size at the sample. The method further includes c) ablating at least a portion of the sample at the position i to form a portion of the surface feature and d) incrementing counter i. The method includes e) repeating steps a) through d) to form the surface feature. The sample is free of a rim surrounding the surface feature.