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: Systems and methods for laser processing using a modified laser beam having a non-Gaussian energy distribution are described herein. In some embodiments, a laser processing system includes a laser source that outputs a laser beam having a Gaussian energy distribution, and a beam modifier positioned in a path of the output beam. The beam modifier controllably modifies the Gaussian energy distribution of the output laser beam along at least one axis perpendicular to the beam's axis of travel. In various embodiments, the laser processing system includes a beam delivery sub-subsystem that operates in a raster mode. In such embodiments, the subsystem can raster the modified beam across a material to form raster lines for transferring an image or pattern to the material.

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: Systems and methods for laser processing using a modified laser beam having a non-Gaussian energy distribution are described herein In some embodiments, a laser processing system includes a laser source that outputs a laser beam having a Gaussian energy distribution, and a beam modifier positioned in a path of the output beam. The beam modifier controllably modifies the Gaussian energy distribution of the output laser beam along at least one axis perpendicular to the beam's axis of travel. In various embodiments, the laser processing system includes a beam delivery sub-subsystem that operates in a raster mode. In such embodiments, the subsystem can raster the modified beam across a material to form raster lines for transferring an image or pattern to the material.

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 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 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: 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: 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: 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.

Abstract: An extruded aluminum gas laser tube assembly (10) has a pair of extruded, elongated, electrically insulated, aluminum electrodes (23,24) adapted to couple to an external RF supply and supported in the laser tube in predetermined spaced-apart relationship relative to each other and to the laser tube (11). The electrode supporting structure is eight pairs of matching, longitudinal, machined grooves (12,21), four pairs at each end of the tube (11) and electrodes (23,24) in each of which pairs is received a cylindrical, insulated, anodized aluminum spacer pin (22) which slidably supports the electrodes in the tube and allows longitudinal expansion of the electrodes relative to the tube substantially without bending.

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 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.