Powder Bed Fusion Additive Manufacturing

Additive manufacturing has often been used for complex, low volume parts. But adoption is increasing with the ability to produce more complex parts by designing products specifically for additive manufacturing and improving the technology and process.  Costs are also being reduced through higher quality, reliability and stability of the process as well as faster production speeds. Powder bed fusion systems utilize a heat source—such as a laser—to sinter or melt ultra-fine layers of material like powdered metal to fuse into the desired shape.

MKS Solutions for Powder Bed Fusion Additive Manufacturing

Challenges in Powder Bed Fusion MKS Solutions
Machine Accuracy Fast, high-power laser measurement and profiling
High precision motorized positioners and advanced motion controllers
High energy optics
Reproducibility and repeatability Fast, high-power laser measurement and profiling
High precision motorized positioners and advanced motion controllers
Long-term Stability Robust, stable optical mounts
Reducing Cost and Process Time Fast, high-power laser measurement and profiling

Your Partner for Additive Manufacturing

  • Long-term partner for additive manufacturing companies
  • Thousands of photonics products and lasers supplied for additive manufacturing
  • Broad range of market-leading products for additive manufacturing: beam profilers, sensors, positioners, optics, opto-mechanics, UV lasers
    • Proven performance
    • Product availability
  • Ability to scale with you
  • Global corporation and presence

Beam Analysis
Motion Control
Optics
Opto-Mechanics
  • High power laser thermal sensors
  • High power beam profilers
  • Laser power/energy meters
  • Linear positioners
  • Vertical positioners
  • Advanced motion controllers
  • High energy mirrors
  • High energy lenses
  • High energy windows
  • Custom optical assemblies
  • Mirror mounts
  • Lens positioners
  • Posts and pedestals

Laser Beam Analysis

Even with the advantages that lasers provide over traditional tools, lasers systems can degrade over time, leading to reduced output power or a change in focus. This, in turn, could result in lower quality laser operations, including sintering. Therefore, it is very important to monitor your laser beam frequently, and the critical parameters of the laser should be checked before and after each important step of the laser manufacturing process.

Causes of Laser System Degradation

  • Thermal Effects
  • Debris from Process
  • Vibrations and Shock
Figure 1. As the laser emerges from the laser source (left), it runs through a variety of laser delivery components, such as free-space optics and process fibers, which can change the power levels and beam profile (center). The laser beam next moves through the laser processing head. Mirrors and lenses and cover glass can also have a significant impact on power levels, size, and shape (right).
Figure 2. The relationship between power density and focus drift, and how a slight drift can have a large effect.

Criteria for Beam Analysis Instruments

There are three types of beam analysis instruments to monitor your laser: (1) sensors and detectors to measure power, (2) power meters to process the information provided by sensors and (3) beam profilers to determine focus position and other beam characteristics. Shown below are the main criteria for choosing such instruments.

Laser Sensors
  • Compatible with laser wavelength
  • Power/energy range/density
  • Beam size
  • Calibrated power measurement
Power Meters
  • Compatible with sensor
  • Connect to system/PC
  • Track process data over time
  • Compare multiple measurements at once
Beam Profilers
  • Measurement of multiple attributes
    • Focal shift
    • Focal spot size
    • Laser power and power density
    • Changes over time
    • Laser propagation characteristics
  • Speed of measurement

Ariel™ All-In-One High Power Laser Sensor

Measures high power industrial lasers in closed and confined spaces.

Ariel™
Spectral Range 450-550 & 900-1100 nm
Power Range 200 mW to 8 kW
Energy Range Up to 2.4 kJ
Maximum Beam Diameter 22 mm (Gaussian)
Response Time 3 s
Interface Options Built-in display
Blue Tooth
USB
Other Features Battery powered (>15 hrs life)
Not water cooled
Compact, industrial package
Detachable diffuser

Focus Quality is Just as Important as Power Level

Figure 3. Relationship between power density and focus spot size. A laser beam with half of the focus spot size results in a four times higher power density.

BeamWatch® Technology

BeamWatch® captures images of the Rayleigh scatter created by the laser beam as it travels through air molecules.

  • Compatible with higher power lasers
  • No cooling required
  • Real time measurements
  • No wear or maintenance

BeamWatch® AM Integrated High Power Beam Profiler

BeamWatch® AM was specifically designed for powder bed fusion. It combines our non-contact laser measurement technology with a NIST-traceable power sensor to measure all critical laser beam parameters in real time on additive manufacturing production lines.

BeamWatch® AM
Spectral Range 1060 to 1080 nm
Power Range 0 to 1000 kW
Energy Range Up to 2.4 kW
Maximum Beam Diameter 6 mm
Minimum Focus Spot Size 50 µm
Accuracy NIST-traceable calibration, ±3%
Communication USB 2.0 and 3.0
Other Features Patented non-contact measurement
Real-time monitoring of beam profile
ISO-compliant measurement results
Fully automated operation

BeamPeek™ Integrated High Power Beam Profiler

BeamPeek™ is a camera-based system that provides simultaneous beam profiling, focal spot analysis and power measurement within seconds.

BeamPeek™
Spectral Range 532 and 1030 to 1080 nm
Power Range 10 to 1000 kW
Maximum Beam Diameter 10 mm
Minimum Focus Spot Size 34.5 µm
Accuracy NIST-traceable calibration, ±5%
Communication USB 2.0 and 3.0
Other Features Integrated camera, meter & beam dump
Measures cross-sectional intensity
Beam dump cooling (no water or fan)
Fully automated operation

Power Meters

Ophir laser power and energy meters work on the smart plug principle. This means that almost any power meter can work – plug and play – with almost any of the wide range of Ophir optical sensors.

Power Meters Virtual Power Meters
centauri
Centauri		 StarBright
StarBright Handheld		 Juno+
Juno+		 EA-1
EA-1
  • Extensive graphic displays on 7-in full color touchscreen display
  • Advanced measurement processing
  • Single- or dual-channel versions
  • USB and RS-232 interfaces, with user-friendly software application
  • Analog and TTL output
  • External trigger input
  • Portable use
  • For transmission checks "in the field"
  • Variety of measurement modes and displays
  • USB & RS-232 interfaces
  • USB connection to use PC as monitor
  • User-friendly software
  • Extensive graphic displays of data
  • Advanced measurement processing
  • Data logging
  • Ethernet adapter enables remote control and monitoring of sensor
  • Telnet, HTTP and UDP protocols supported
  • Interact with sensor through custom software or MKS user-friendly software
  • Data logging

Motion Control

Galvanometer Scanners and Linear Positioners

Galvos
  • Advantages
    • Used to steer laser
    • Fast scanning (meters/sec) with sharp corners
  • Limitations
    • Limited field of view (~100-200 mm)
    • Limited focal spot size (10-20 µm)
Linear Positioners
  • Advantages
    • Used to position target or…
    • Used to position galvo(s)
    • Large field of view
    • Allows tight focal spots (<10 µm)
  • Limitations
    • Not as fast as galvos

Combined Galvo-Linear Positioners System

  • Combines speed of galvos with FOV allowed by positioners
  • Galvo and positioners can be synchronized with advanced motion controller
  • Enables "stitching":
    • Galvo process for "cells"
    • Positioners place next cell as target
    • Repeat galvo process
Galvos Linear Positioners Combined System
Speed & Acceleration Fast Not as fast Fast
Field of View (FOV) Limited Large Large
Focal Spot Size Limited Tighter Tight
  • MKS offers a full range of positioners and motion controllers
  • Galvos purchased separately – MKS controllers can interface with galvos

Guaranteed Motion Control Performance

  • Stages that MKS ships meet or exceed the guaranteed specifications
  • Metrology reports included with each stage (ASME B5.57 and ISO 230-2 standards)
  • Typically, the product will perform ~2x better than the guarantee

IDL-LM Series Linear Motor Positioners

Highest load capacity and speed of all linear motor positioners for demanding production environments

IDL-LM Series
Travel Range 100 to 1,200 mm
Speed 2 m/sec
Load Capacity 450 to 2,000 N
Pitch ±0.15 to ±0.65 µrad
Yaw ±0.15 to ±0.4 µrad
Accuracy ±2 to ±5 µm
Repeatability ±0.25 to ±0.5 µm
Other Features Ironless Linear Motor
Recirculating ball bearings
Industrial grade hard covers

GTS-V Series High Precision Vertical Positioner

Highly accurate, repeatable and fast vertical motion in a compact unit

GTS-V Series
Travel Range 30 to 70 mm
Speed 5-10 m/sec
Load Capacity 40 to 70 N
Pitch ±0.25 to ±0.80 µrad
Roll ±0.25 to ±0.80 µrad
Accuracy ±0.75 to ±1.75 µm
Repeatability ±0.1 to ±0.5 µm
Other Features Direct vertical guiding system
Folded DC motor
Unobstructed access to payload

IMS Series Long-Travel Aluminum Linear Positioners

High load capacity, long travel, fast movement capable of high-duty cycles in industrial applications

Stepper Motor DC Motor
Travel Range 300 to 600 mm
Speed 100 m/sec 200 mm/sec
Load Capacity 600 N
Pitch ±37 to ±50 µrad
Yaw ±15 to ±30 µrad
Accuracy ±2.5 to ±4 µm
Other Features Double-row recirculating ball bearings
Linear motor version available

ILS Series Mid-Travel Aluminum Linear Positioners

High load capacity, mid-travel, fast movement capable of high-duty cycles in light industrial applications

Stepper Motor DC Motor
Travel Range 50 to 250 mm
Speed 50 m/sec 100 mm/sec
Load Capacity 250 N
Pitch ±15 to ±42 µrad
Yaw ±12 to ±25 µrad
Accuracy ±0.6 to ±1.7 µm
Other Features Double-row recirculating ball bearings
Linear motor version available

Motion Controllers

XPS-D
XPS-D		 XPS-RLD
XPS-RLD
  • High performance, complex motion trajectories
  • Up to 8 axes
  • Extensive analog and digital I/O
  • Can synchronize galvos and positioners
  • Best for the most demanding applications
  • High performance, complex motion trajectories
  • Up to 4 axes
  • Analog and digital I/O
  • Can synchronize galvos and positioners
  • Good for demanding R&D and low volume production

Optics

Criteria for Selecting Optics

  • Wavelength
  • Laser Damage Threshold
    • Substrate Material
    • Coating
  • Reflectivity/Transmission
  • Size and Shape

High-Energy Laser Mirrors

Very high reflectivity and damage thresholds

High-Energy Laser Mirrors
Wavelength (nm) 1064 nm
CW Damage Threshold 3 kW/cm2
Pulsed Damage Threshold 45 J/cm2 @ 10 ns, 20 Hz
Reflectivity Rs > 99.7%
Rp > 99%
Diameter 1 and 2 in.
Substrate Material UV Grade Fused Silica
Angle of Incidence 45°

High-Energy Singlet Spherical Lenses

Very high transmission and damage thresholds

High-Energy 1064 nm Lenses
Wavelength (nm) 1064 nm
Pulsed Damage Threshold 15 J/cm2 @ 20 ns, 10 Hz
Average Reflectivity per Surface < 0.25%
Diameter 1 inch
Substrate Material High Purity Fused Silica
Shapes Plano-Convex (Standard Product)
Other Shapes Available as Custom Orders

Fused Silica Singlet Spherical Lenses

Good performance and value over broad spectral ranges

Fused Silica 1064 nm Lenses
Wavelength (nm) 1064 nm
Pulsed Damage Threshold 12 J/cm2 @ 10 ns, 10 Hz
Reflectivity per Surface Rmax< 0.25%
Diameter 0.25 to 2 in.
Substrate Material UV Fused Silica
Shapes Plano-Convex
Bi-Convex
Plano-Concave
Bi-Concave

1-µm Fiberlens™ Aspheric Lenses

Improved performance over spherical lenses for high power 1 µm industrial fiber lasers

Fiberlens™ Aspheric Lenses
Wavelengths 1030-1090 nm
Pulsed Damage Threshold 20 J/cm2
Reflectivity per Surface < 0.2%
Diameters 12 to 300 mm
Effective Focal Lengths 20 to 500 mm
Substrate Material High Purity UV Fused Silica
Shapes Aspherical-Plano
Aspherical-Spherical
Aspherical-Aspherical

1 µm High Power Singlet and Doublet Lenses

High damage thresholds for high power 1-µm industrial fiber lasers

1 µm Lenses Series
Wavelengths 1030-1090 nm
Pulsed Damage Threshold 20 J/cm2
Reflectivity per Surface < 0.2%
Diameters 1 to 2 inch
Effective Focal Lengths 100 to 229 mm
Substrate Material High Purity UV Fused Silica
Other Features Coating can be adjusted for other wavelengths (e.g., 266, 356, 532 nm)

1 µm High Power Optical Windows

High damage thresholds for high power 1-µm industrial fiber lasers

1 µm Optical Windows
Wavelengths 1030-1090 nm
Pulsed Damage Threshold 20 J/cm2
Reflectivity per Surface < 0.2%
Diameters 21.5 to 55 mm
Thickness 1.5 to 8 mm
Substrate Material High Purity UV Fused Silica

1 µm Collimating & Focusing Assemblies

  • Compatible with leading OEM lasers
  • Standard products for 100, 125, 150 and 200 mm focal lengths
  • Customization upon request

Motorized Zoom Lenses

  • Custom designed for laser cutting heads
  • 1X-4X magnification range
  • Continuous zoom
  • >97% total transmission
  • -15 to +20 mm focus range
  • ½-sec focus time for full range

Opto-Mechanics

Criteria for Selecting Optical Mounts

  • Resolution/Sensitivity
  • Long Term Stability
  • Lockable
  • Size and Shape

Suprema™ Stainless Steel Mirror Mounts

The industry's best thermal performance for long-term stability

Suprema®
Optic Diameters 0.5, 1 and 2 in.
Resolution 50, 100, 127 and 254 TPI
Angular Range ±4° to ±7°
Material Stainless Steel
Drive Types Knob
Hex Key
Lockable Versions Yes
Other Features Clear-edge versions
Front- and rear-loading versions
Right- and left-handed configurations

HVM Top-Adjust Industrial Mirror Mounts

For use in compact spaces so your hands do not have to cross the beam path for adjustment.

HVM Series
Optic Diameters 0.5, 1 and 2 in.
Resolution 80 and 100 TPI
Angular Range ±2.5°, ±3° and ±3.5°
Material Stainless Steel
Anodized Aluminum
Drive Type Hex Key
Lockable Yes
Other Features Alignment pin holes
Front- and rear-loading versions

MFM Flexure Mirror Mounts

Shock resistant, designed for "set and forget" applications.

MFM Series
Optic Diameters 0.5, 0.75 and 1.0 in.
Resolution 80 and 100 TPI
Angular Range ±2.5°
Material Stainless Steel
Drive Type Hex Key
Lockable No
Other Features Shock resistant
Front- and rear-loading versions
Adhesive wells for permanent mounting

M Series Mirror Mounts

The industry’s most affordable mirror mounts

M Series
Optic Diameters 0.5, 1.0 and 2.0 in.
Resolution 100 TPI
Angular Range ±4°
Material Aluminum
Drive Type Knob or Hex Key
Other Features Clear-edge Versions
Front- and rear-loading versions
Square or D-shaped optic versions
Mounting hole located directly below the optical axis

LP Precision Multi-Axis Lens Positioners

Highest performing lens positioners

LP Series Lens Positioners
Optic Diameters 0.5, 1.0 and 2.0 in.
Resolution 100 TPI (Z-axis: 80 TPI)
Adjustments XY, XYZ, XYZθxθy
Material Aluminum
Drive Type Knob w/ Hex Hole & Knurled Ring
Lockable Yes
Other Features Zero-free play XY mechanism
Adapters for other optics

Compact Lens Positioners

Ideal solution for applications with limited table space

Compact Lens Positioners
Optic Diameter 0.5, 1.0, and 2.0 in.
Resolution 100 TPI
Adjustments XY, XYZ, XYθz, XYZθxθy, XYZθxθyθz
Material Anodized Aluminum
Drive Type Hex Key
Lockable Version Yes
Other Features Adapters for other optics
Alignment pin holes

A-Line™ Fixed Position Lens Mounts

Fast, easy and economic mounting, aligning and focusing of optics

A-Line™ Fixed Lens Mounts
Optic Diameters 0.5 to 3.0 in.
Maximum Optic Edge Thickness 3, 6, 7 and 9 mm
Material Aluminum
Other Features Self-aligning design
Large clear aperture
Compatible with A-Line lens alignment system

PX Forkless Optical Pedestals

Long-term stability of a pedestal at 1/3 the space

PX Forkless Pedestals
Diameter 1.0 in. (1.25 in. flange)
Heights 1, 2, 3 and 4 in.
Material Stainless Steel
Other Features Accessories for varying heights and mounting configurations

Vibration Control

The Industry Standard for Vibration Control

  • Established in 1969, Newport developed steel-clad, honeycomb core tables
  • Extensive offering of tables, workstations, isolation systems and vibration control
  • Custom table solutions

Honeycomb Optical Breadboards

High performing, robust platform for demanding applications

PG Series SG Series
Sizes 12 x 24 in. to 36 x 72 in. 12 x 12 in. to 48 x 96 in.
Thickness 2.3 or 4.3 in.
Working Surface 4.8 mm thick ferromagnetic 430 stainless steel
Damping Patented modal damping plus Broadband damping Broadband damping
Surface Flatness ±0.004 in. over 2 ft. square)
Other Features Vertically bonded trussed hexagonal honeycomb core
Individually sealed mounting holes

NewDamp™ Elastomeric Vibration Isolators

Supports and dampens high acceleration amplitudes

NewDamp™ Elastomeric Isolators
Minimum Loads 6-45 kg
Load Capacity 8 to 200 kg (per isolator)
Loss Factor 0.5 to 0.8 in 10-100 Hz range
Height 1.32 to 3.28 in.
Base Size 2.4 x 2.4 to 4.5 x 4.5 in.
Other Features Constant natural frequency design
Fast settling times
Cleanroom compatible
Breadboard, Microlock and X95 compatible

RS2000 Optical Table Tops

High performance passive damping for demanding applications

RS2000 Table Tops
Lengths 3 to 6 ft.
Widths 5 to 16 ft.
Thickness 8 to 24 in.
Working Surface 4.8 mm thick ferromagnetic 430 stainless steel
Damping 2 precision-tuned dampers plus broadband damping
Surface Flatness ±0.004 in. over 2 ft. square)
Other Features Super rigid trussed honeycomb core
Individually sealed mounting holes
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