Abstract: Systems and methods for laser processing systems and associated methods for using and manufacturing such systems are disclosed herein. In some embodiments, a laser processing system includes a controller, a laser source, a material support, and a beam delivery subsystem operably coupled to the controller. The beam delivery subsystem comprises an optical carriage assembly configured to receive and modify a laser beam from the laser source, and direct the laser beam toward a material to be processed carried by the material support. The optical carriage assembly is further configured to focus the laser beam within a material processing field to obtain an adjustable power density within a material processing plane and achieve an optimal selected condition for the material to be processed.

Abstract: Embodiments of methods and systems for distributing laser energy are disclosed herein. A system for dispensing laser energy by one or more laser energy sources in accordance with one embodiment of the present technology includes a laser energy credit transferring component configured to communicate with a laser energy source. The laser energy source is configured for producing and dispensing laser energy. The laser energy credit transferring component is further configured to receive a request from the laser energy source for laser energy and transfer laser energy credits to the laser energy source. The laser energy credits enable the laser energy source to dispense a corresponding amount of laser energy.

Abstract: Embodiments of laser material processing systems with fire suppression are disclosed herein. A laser material processing system configured in accordance with one embodiment includes a laser material processing region, at least one sensor disposed in the laser material processing region, and at least one suppressant delivery port positioned in or adjacent to the laser material processing region. The sensor is configured to detect the presence of self-sustained combustion in the laser material processing region, and a suppressant delivery port is configured to deliver suppressant to suppress the self-sustained combustion when at least one of the sensors detects self-sustained combustion.

Abstract: Laser material processing systems having beam positioning assemblies with fluidic bearing interfaces and associated systems and methods are disclosed herein. In one embodiment, a laser material processing system includes a beam positioning assembly configured to position a laser beam. The beam positioning assembly includes a first linear guide having first guide surfaces and a second linear guide having second guide surfaces. The first linear guide is moveably coupled to the first linear guide via the first guide surfaces. The second linear guide is moveably coupled to a carriage via the second guide surfaces. At least one fluidic bearing interface is positioned to prevent direct physical contact between the second linear guide and at least one of the first guide surfaces and/or between the carriage and at least one of the second guide surfaces.

Abstract: Embodiments of methods and systems for distributing laser energy are disclosed herein. A method configured in accordance with one embodiment includes establishing communication with a laser energy source configured to dispense laser energy, and enabling the laser energy source to dispense laser energy by transferring laser energy credits to the laser energy source. The transferred laser energy credits correspond to an amount of enabled laser energy.

Abstract: Embodiments of flexible laser manufacturing systems are disclosed herein. A flexible laser manufacturing system configured in accordance with one embodiment includes a plurality of laser processing stations. Each laser processing station can include a laser source configured to generate a laser beam for processing target material, and a first controller coupled to the laser source. The flexible laser manufacturing system also includes a second controller coupled to the first controller of the individual laser processing stations. The second controller is configured to monitor and instruct each of the first controllers for processing target material of each of the corresponding laser processing stations.

Abstract: Laser processing systems for processing one or more materials or combination of materials with composite laser energy and associated systems and methods are disclosed herein. In several embodiments, for example, a laser processing system includes one or more laser sources that provide a first plurality of first laser beams and preconditioning optics that combine the first laser beams into a first composite beam. The system also includes recomposition optics that separate the first composite beam into second plurality of second laser beams and combine the second laser beams into a second composite beam. The system further includes beam modification optics that modify wave fronts of one or more of the individual second laser beams such that the second composite beam has one or more beam characteristics that are modified relative to corresponding beam characteristics of the first composite beam. For example, the second laser beams of the second composite beam can focus at a common focusing plane.

Abstract: Embodiments of an air-cooled gas laser with a heat transfer assembly are disclosed herein. A laser configured in accordance with one embodiment includes a laser superstructure and a laser superstructure having an opening and a cavity accessible through the opening, and an electrode assembly. The electrode assembly is configured to be received into the cavity, and includes a frame and an electrode biasedly coupled to the frame and electrically insulated therefrom.

Abstract: Embodiments of an air-cooled gas laser are disclosed herein. A laser configured in accordance with one embodiment includes a laser superstructure, an optical assembly, and an elongated thermal decoupler member having a first end portion fixedly coupled to the optical assembly and a second end portion fixedly coupled to the laser superstructure. The laser further includes an optical assembly that includes a first holder member fixedly coupled to the first end portion of the thermal decoupler, a second holder member pivotally coupled to the first holder member and fixedly coupled to the laser superstructure, and a flexible seal having a portion coupled to the laser structure and disposed at least between the first holder member and the second holder member.

Abstract: Embodiments of an air-cooled gas laser with heat transfer resonator optics are disclosed herein. A laser configured in accordance with one embodiment includes resonator optics having an optical element, a first heat sink element in surface-to-surface contact with a first side surface of the optical element, a second heat sink element in surface-to-surface contact with a second side surface of the optical element, and a carrier member carrying the optical element and the first heat sink element, and including a forward facing surface in surface-to-surface contact with the backside surface of the optical element. The resonator optics further include first and second biasing elements biasedly coupled to the carrier member and configured to bias the first and second heat sink elements against the first side and second side surfaces, respectively, of the optical element.

Abstract: Embodiments of multi-stage air filtration systems are disclosed herein. A filtration system configured in accordance with one embodiment includes at least a first filter and a second filter arranged in series in an exhaust stream. The first filter is arranged to hold a first active media in the exhaust stream, the second filter is arranged to hold a second active media in the exhaust stream, and the active media is selected to remove one or more contaminants known to be in the exhaust stream. The system also includes at least one sensor arranged to detect the presence of the one or more contaminants downstream of the first filter and/or the second filter.

Abstract: Laser material processing systems having beam positioning assemblies with fluidic bearing interfaces and associated systems and methods are disclosed herein. In one embodiment, a laser material processing system includes a beam positioning assembly configured to position a laser beam. The beam positioning assembly includes a first linear guide having first guide surfaces and a second linear guide having second guide surfaces. The first linear guide is moveably coupled to the first linear guide via the first guide surfaces. The second linear guide is moveably coupled to a carriage via the second guide surfaces. At least one fluidic bearing interface is positioned to prevent direct physical contact between the second linear guide and at least one of the first guide surfaces and/or between the carriage and at least one of the second guide surfaces.

Abstract: Embodiments of multi-stage air filtration systems are disclosed herein. A filtration system configured in accordance with one embodiment includes at least a first filter and a second filter arranged in series in an exhaust stream. The first filter is arranged to hold a first active media in the exhaust stream, the second filter is arranged to hold a second active media in the exhaust stream, and the active media is selected to remove one or more contaminants known to be in the exhaust stream. The system also includes at least one sensor arranged to detect the presence of the one or more contaminants downstream of the first filter and/or the second filter.

Abstract: Embodiments of recirculating filtration and exhaust systems for material processing systems are disclosed herein. A material processing system configured in accordance with one embodiment includes an enclosure for processing a workpiece, the enclosure having an enclosure inlet and an enclosure outlet. The system also includes a first flow path fluidly coupled to the enclosure inlet and the enclosure outlet, and a first filtration assembly in the first flow path. The first filtration assembly draws airflow from the enclosure and returns the airflow to the enclosure. The system further includes a second flow path in fluid communication with the first flow path upstream from the enclosure inlet, and a second filtration assembly in the second flow path. The second filtration assembly draws airflow from the first flow path and returns airflow to the first flow path.

Abstract: Slab lasers and method for producing high power coherent laser radiation of good quality. In one embodiment, a slab laser comprises a slab laser medium, an energy source configured to deliver energy to the laser medium, and first and second optical elements. The first optical element has a first reflective surface at a first boundary of the laser medium, and the second optical element has a second reflective surface at a second boundary of the laser medium. The first and second reflective surfaces face each other across the length of the laser medium, and at least one of the first and second optical elements includes a plurality of reflective regions configured to modify the phase distribution of the incident laser radiation propagating from the reflective regions. The first and second reflective surfaces are also positioned at an angle relative to each other to form a laser resonator.

Abstract: Laser beam positioning systems for material processing and methods for using such systems are disclosed herein. One embodiment of a laser-based material processing system, for example, can include (a) a radiation source configured to produce a laser beam and direct the beam along a beam path, and (b) a laser beam positioning assembly in the beam path. The laser beam positioning assembly can include a first focusing element, first and second reflective optical elements, and a second focusing element. The first focusing element can focus the laser beam to a first focal point between the first and second reflective optical elements. The first and second reflective optical elements can direct the laser beam toward a material processing area while the laser beam has a decreasing or increasing cross-sectional dimension. The second focusing element can focus the laser beam and direct the beam toward the material processing area.

Abstract: Embodiments of recirculating filtration and exhaust systems for material processing systems are disclosed herein. A material processing system configured in accordance with one embodiment includes an enclosure for processing a workpiece, the enclosure having an enclosure inlet and an enclosure outlet. The system also includes a first flow path fluidly coupled to the enclosure inlet and the enclosure outlet, and a first filtration assembly in the first flow path. The first filtration assembly draws airflow from the enclosure and returns the airflow to the enclosure. The system further includes a second flow path in fluid communication with the first flow path upstream from the enclosure inlet, and a second filtration assembly in the second flow path. The second filtration assembly draws airflow from the first flow path and returns airflow to the first flow path.

Abstract: Laser-based material processing systems and methods for using such systems are disclosed herein. In one embodiment, for example, a laser-based material processing system includes a workpiece support, a positioning assembly over at least a portion of the workpiece support, and a laser. The system includes a laser beam director carried by the positioning assembly to direct a beam generated by the laser toward the workpiece support. The system also includes a dispensing unit carried by the positioning assembly to discharge a material toward the workpiece support. The system further includes a controller operably coupled to the positioning assembly, the laser beam director, and the dispensing unit. The controller can be configured to move the laser beam director and the dispensing unit relative to the workpiece support such that (a) the beam is directed toward a first portion of the workpiece support, and (b) the dispensing unit discharges material toward the first portion of the workpiece support.

Abstract: Laser-based material processing systems, exhaust systems, and methods for using such systems are disclosed herein. One embodiment of a laser-based material processing system can include an exhaust assembly configured to remove contaminants from a material processing area. The exhaust assembly can include a vacuum source and an exhaust plenum carried by a moveable arm of a gantry-style laser beam positioning assembly. The moveable arm can extend along a first axis and can be moveable along a second axis generally normal to the first axis. The exhaust plenum can extend lengthwise in a direction generally parallel with the first axis. The exhaust assembly can also include an intake slot extending lengthwise along the exhaust plenum across at least a portion of the material processing area. The exhaust assembly can further include one or more flexible exhaust ducts in fluid communication with the vacuum source and the exhaust plenum.

Abstract: Laser conversion systems and methods for converting laser systems for operation in different laser safety classification modes are disclosed herein. In one embodiment, a laser system includes a laser configured to emit radiation greater than about 5 mW and an exterior housing containing the laser. The exterior housing has a section configured to be in a first arrangement in which the laser system is classified as a class I system and a second arrangement in which the laser system is classified as a class IV system. The laser system further includes a conversion module operably coupled to the laser system and the section. The conversion module is configured to enable one or more regulatory features required for class IV operation of the laser system when the section is in the second arrangement and disable the regulatory features required for class IV operation of the laser system when the section is in the first arrangement.