Demonstrating Flexible, Powerful 5-axis Laser Micromachining

A Novel Controls Approach to 5-axis Laser Micromachining

Five-axis scan heads offer fast and flexible solutions for generating precise holes, contoured slots and other geometries with fully defined cross sections. With a suitable system, it is possible to control the entire micro-machining process - the laser, scan head and workpiece positioning - to produce macro-sized components to sub-micrometer dimensional tolerances.

This paper outlines the working principles of one such 5-axis laser precession scan head, Aerotech's AGV5D, combined in a system with precision linear motion axes and controls.

It explains the system's working principles, including the powerful G-code based programming approach that enables standard CAM software and built-in motion functions to perform complex hole drilling and milling operations at a micrometer scale.

5-axis Laser Motion Systems: Working Principle

Fully understanding the advantages of using a 5-axis laser motion system for micro-drilling and milling - such as the one shown in Figure

1- and how its accuracy is quantified in such processes requires a sound understanding of the example system's working principle and how it is programmed.

The example system referenced in this paper uses Aerotech's AGV5D 5-axis precession scanner to manipulate a laser beam in five degrees of freedom (DOF), as shown in Figure 2:

• X and Y Spot placement within the field of view at any Z height (2-DOF)

• Z-Spot focus control at any position (1-DOF) A - Beam taper angle OR tilt away from Z (1-DOF)

• C - Beam clock angle OR rotation about Z (1-DOF)

The AGV5D scanner's maximum operating volume is a 2 mm diameter circle (X and Y) over a height of 2 mm (Z). The beam taper angle (A) is +/-9° with a beam clock angle (C) of 360° continuous rotation.