Abstract: A laser includes a laser source and an power source arranged such that both components have substantially the same cross-section, with cooling fins arranged axially along the length of each element. The components are arranged end-to-end in a series to form an assembly with substantially the same cross-section along the entire length of the assembly. A shroud mounted along the assembly forms a single air channel directing air from a fan along the entire length of the assembly, for cooling both the power source and the laser source with the total air flow from the at least one fan. The laser source and the power source are arranged in series such that the laser source is cooled first, and the subsequent air flow, although slightly warmer from cooling the laser source, is sufficient to cool the power source.

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 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 toward a material processing area, 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 (e.g., movable mirrors), 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 the material processing area while the laser beam has a decreasing or increasing cross-sectional dimension (e.g., diameter).

Abstract: Gas lasers including nanoscale catalysts and methods for producing such lasers are disclosed herein. In one embodiment, a gas laser includes a gas containment structure having a gas discharge region and a laser gas medium in the gas discharge region. The gas laser also includes a plurality of optical elements spaced apart from each other at opposite ends of the gas discharge region to form a laser resonator. The gas laser further includes a nanoscale catalyst proximate to and in communication with the gas discharge region to modify oxidation and/or decomposition processes of selected components of the laser gas medium. In one embodiment, the nanoscale catalyst can include a metal-oxide support substrate carrying a plurality of nanoscale particulates. The nanoscale particulates can be composed of one or more of the following: gold, silver, or platinum, and have an average size of about 1-50 nm.

Abstract: An air cooled laser includes a laser housing with a laser module and heat sinks therein connected to a high pressure blower structure for causing an airflow to remove heat from the heat sinks and maintain the laser module at a stable operating temperature.

Abstract: Gas lasers including nanoscale catalysts and methods for producing such lasers are disclosed herein. In one embodiment, a gas laser includes a gas containment structure having a gas discharge region and a laser gas medium in the gas discharge region. The gas laser also includes a plurality of optical elements spaced apart from each other at opposite ends of the gas discharge region to form a laser resonator. The gas laser further includes a nanoscale catalyst proximate to and in communication with the gas discharge region to modify oxidation and/or decomposition processes of selected components of the laser gas medium. In one embodiment, the nanoscale catalyst can include a metal-oxide support substrate carrying a plurality of nanoscale particulates. The nanoscale particulates can be composed of one or more of the following: gold, silver, or platinum, and have an average size of about 1-50 nm.

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.

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 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 also includes a laser beam director carried by the positioning assembly to direct a beam generated by the laser toward the workpiece support. The system further includes a dispensing unit carried by the positioning assembly to discharge a material toward the workpiece support. The dispensing unit can be configured to discharge a number of different materials onto a workpiece carried by the workpiece support.

Abstract: A laser material processing system and method focus a laser beam to a smaller spot size with a high power density using a movable beam expander to provide high resolution laser beam for engraving and/or cutting. A movable beam focusing assembly containing a beam expanding optics and a beam focusing optics is a part of a motion system providing a high power density focused beam within the material processing area minimizing size and weight of the laser beam positioning optics and avoiding the problems inherent in handling and positioning a larger diameter beam.

Abstract: A laser includes a deformable tube holding an electrode assembly that includes conformable spacers. The spacers are deformed by compression of the tube into good surface contact with the electrodes and the tube walls, thereby providing the necessary path for heat removal from the plasma in order to maintain the required operating temperature for adequate performance of the laser.

Abstract: A laser system 20 enables quickly releasing and replacing a laser source 41 mounted in a laser compartment 40 by interfacing engaging members 32,43 of the platform 40 and source 41, respectively to place the pre-aligned beam 42 in operative relation with the pre-aligned beam delivery system 31 and closing the compartment with a latchable 45 cover 44 without the use of any tools and without the need for any additional beam alignment.

Abstract: Each one of multiple laser sources are independently separately mounted on a laser material processing platform and their beam paths are combined by a combiner which includes one or more optical elements mounted in the laser material processing platform which make the beam paths parallel and colinear. The combined beams are then moved in X and Y planes relative to a workpiece supported in the laser material processing platform under the control of a computer in the performance of work in accordance with a work program. The beam path of each laser source and the optical axis of the beam delivery system are each pre-aligned to the same predetermined reference and automatically coincide upon installation such that these components are rapidly and interchangeably interfaceable. The beams are orthogonally polarized and the optical elements of the combiner transmit one beam while reflecting another beam. While two laser beams are shown, an infinite number of laser beams may be used.

Abstract: The beam path [80] of a laser source [10] is first pre-aligned to a predetermined reference, and then the optical axis [90] of the beam delivery system [40, 50] of a laser material processing platform [20] is pre-aligned to the pre-aligned beam path of the laser source such that the two coincide. If the laser beam [80] is invisible, a laser simulator [72] having a visible pre-aligned beam may be used instead.

Abstract: A portable laser processing module is adapted to be quickly and easily independently interfaced between a stationary exhaust docking station for fume extraction during in-office use and a portable air processing module for fume extraction during field use. A passageway in the housing connects the work area to an exhaust port which communicates with an inlet port in the docking station or the portable air processing module and ultimately to a blower unit in a facility or in an internal compartment in the portable air processing module which maintains a negative pressure in the work area for removal of fumes, debris, particulates, and contaminants therefrom. Guides are receivable in recesses between the laser processing module and the docking station or portable air processing module for guiding the module thereon, and a gasket seals the exhaust port and inlet port when the module is supported on the docking station or the portable air processing unit.

Abstract: A computer controlled laser material processing system has a plurality of laser sources the beams of which are selectively operable between two modes. In a first raster engraving mode the beams are separated and independently controllable in synchronism with the motions of a beam delivery system to form plural, parallel, spaced apart scan lines on the surface of the workpiece for affecting the surface at high speed. In a second vector cutting mode the beams are combined such that they are collinear and have a power approximately equal to the sum of the powers of each individual laser source for cutting the surface at high power.

Abstract: A gas laser RF power supply has two RF oscillators operating at different frequencies, the first frequency to provide maximum RF voltage to the plasma tube prior to ignition, and the second frequency to provide optimum power for sustaining CW or pulse operation of the laser. The oscillator outputs are modulated to control power to the tube, the one in the form of RF pulses at the first frequency and at a power level below the laser emission threshold, and the other in CW or pulse form at the second frequency at a laser gas medium excitation level above the laser emission threshold. The first frequency is the resonance frequency of the tube prior to plasma ignition and the frequency of minimum average RF power required for a reliable ignition. The second frequency is the most efficient operating frequency for the plasma ignited and kept ionized by the pulses of the first frequency and provides maximum output laser power.

Abstract: A pair of elongated, parallel electrodes (91,92) are insulatively mounted within a tubular housing (111) filled with a laser gas mixture between an arrangement of reflective optical elements (120,150) sealingly mounted at each end of the housing. The electrodes form a rectangular gas discharge area (40) the minimum spacing (a) between which is the diameter of the fundamental free-space mode of the stable, laser resonator (17) formed in the gap when the electrodes are rf excited (13). A multi-pass optical configuration (30,50) uses the full width (b) of the active medium to produce a high power, compact laser (10,200). Deformable support rings (97) are compressed to push the electrodes apart against small cylindrical spacers (99) abutting the inner walls of the housing to maintain the electrodes' spatial relationship. The rf feeds (103) sealingly (112) connected to the electrodes through the housing without disturbing the uniform distribution of forces on the electrodes.

Abstract: A gas laser design (10) includes, an elongated sealed tube (21) filled with a gas, a power supply for exciting the gas, an optical resonator (24,25) for producing directional optical energy, and a fan/electronics package assembly (50), all of which are surrounded and enclosed by an external housing (30,70,90) forming a passageway in the space between the tube and the housing for providing cooling air therethrough. The passageway is divided into two physically separated cooling air paths by a horizontal surface (21a or 41). The lower space is a dual L-shaped path defining the first cooling air path downwardly at the inlet end of the tube in the vertical air channels (31,32) formed by the contoured shape of the tube and rearwardly (33) through the spaces (27,29) between the horizontal fins (26,28) of the tube to an outlet (101) at the rear of the tube.

Abstract: A pair of elongated, parallel electrodes (91,92) are insulatively mounted within a tubular housing (111) filled with a laser gas mixture between an arrangement of reflective optical elements (120,150) sealingly mounted at each end of the housing. The electrodes form a rectangular gas discharge area (40) the minimum spacing (A) between which is the diameter of the fundamental free-space mode of the stable, laser resonator (17) formed in the gap when the electrodes are rf excited (13). A multi-pass optical configuration (30,50) uses the full width (B) of the active medium to produce a high power, compact laser (10,200). Deformable support rings (97) are compressed to push the electrodes apart against small cylindrical spacers (99) abutting the inner walls of the housing to maintain the electrodes' spatial relationship. The rf feeds (103) sealingly (112) connected to the electrodes through the housing without disturbing the uniform distribution of forces on the electrodes.