Deformable mirror technology takes laser welding and 3D printing to new heights

Yongcui Mi has developed a new technology that enables real-time shaping and control of laser beams for laser welding and directed energy deposition using laser and wire. The innovation is based on the same mirror technology used in advanced telescopes for astronomy.

In a few years, this new technology could lead to more efficient and reliable ways of using high-power lasers for welding and directed energy deposition with laser and wire. The manufacturing industry could benefit from new opportunities to build more robust processes that meet stringent quality standards.

“We are the first to use deformable mirror technology for this application. The mirror optics can handle multi-kilowatt laser power, and with the help of computer vision and AI, the laser beam can be shaped in real time to adapt to variations in joint gaps,” explains Yongcui, a newly minted Ph.D. in Production technology from University West.

The industry currently faces significant challenges in high power laser welding without filler wire. Defects often occur in the welds due to variations in joint gap widths.

Dynamic laser beam shaping

“To achieve a strong and flawless joint, the laser beam shape needs to adapt to the varying widths along a weld seam. With this technology, the beam can be dynamically shaped during the welding process to bridge joint gaps up to 0.6 millimeters when welding steel plates that are 2 millimeters thick,” says Yongcui.

“The laser beam shape can change within 10 milliseconds, and using various elliptical beam shapes, we can also achieve higher weld quality compared to traditional circular static beams. Our tests show that we can reduce deformations in the workpiece by up to 80%.”

Yongcui has also tested the new technology for directed energy deposition with laser and wire. Here too, dynamic laser beam shaping can create more efficient and reliable processes for high power lasers.

Saves time and money

“The results of my research show that dynamic laser beam shaping holds great potential for both laser welding and directed energy deposition with laser and wire. This technology makes the process more flexible and achieves higher quality. Additionally, it significantly reduces material waste and energy consumption, saving both time and money.”

The deformable mirror was developed in close collaboration with Dynamic Optics, an Italian company that primarily manufactures mirror optics for advanced telescopes used by astronomers. The mirror technology was developed in the 1950s by the University of Padua in Italy and has since enabled telescopes to deliver more precise images of stars, planets, and other celestial bodies.

Custom-designed mirrors

“The mirror for our project has been customized for our specific application. Integrating, debugging, and validating a prototype of the cutting-edge technology was the most challenging and time-consuming part of the research,” says Yongcui.

Yongcui has also collaborated with industrial partners such as GKN Aerospace, Brogren Industries, and Procada. The technology has garnered significant interest from industries working with high-powered lasers, including manufacturers of next-generation aircraft engines, electrified vehicles, and other demanding industrial applications.

“Further research is now needed to make the technology ready for full-scale production in a few years. I hope to continue my research and contribute broader and deeper knowledge in this field.”