Fiber Lasers for Medical Applications · Rtbl Repeatable process High accuracy High reliability...

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AILU – PHOTONEX 0816th October 2008

Fiber Lasers for Fiber Lasers for Medical ApplicationsMedical Applications

Dr Jack Gabzdyld l d

Not to be distributed without prior consent of SPI Lasers plc

Product Line Manager – Pulsed Lasers

GeneralGeneral Advantages of Fibre LasersAdvantages of Fibre Lasers

Beam Quality & StabilityDiffraction-limited beam Small spot size (<10um possible)N i ti d ift th l l i blNo pointing drift nor thermal lensing problemsFlexible beam delivery

All Fiber Integrated: No free space optics to adjust / tune Zero-maintenance solid-state systemCompact and easy to integrate


Operational BenefitsLow-power consumption (wall-plug efficiency)No gases requiredNo consumable itemsFewer support specialists

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R4 High Power LaserR4 High Power Laser

25-200W Air Cooled

Features

100-400W Water Cooled


- CW or Modulated to 100 kHz (modulated pulses <5µs to CW)

- TEM00 (M² <1.1), <BPP 0.37 mm.mrad

- Central Emission Wavelength: 1070 ± 10nm

-High stability laser (typically <±0.5% output power variation)

G3 Pulsed laser rangeG3 Pulsed laser range

Features of 10 & 20 W/RM, 12 & 20W/HS and 30W/HM


Features- Up to 500 kHz pulse repetition frequency

- Pulsed and CW operation- Pulse width variable (across 25 pre-set waveforms)

- Peak Emission Wavelength: 1064 ± 5 nm

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Compact Laser ModuleCompact Laser Module1090/1550/1565nm

CLM 1090nm CLM 1550/1565nm


CLM –1090nm

Features-CW or Modulated to 50kHz

(modulated pulses 10µs to CW)- TEM00 (M² <1.1), BPP 0.38 mm.mrad

CLM –1550/1565nm

Features- Up to 20W optical output power

- Diffraction limited to beam quality (M2<1.1)

Why a Fibre Laser ? Why a Fibre Laser ?

Key differentiators vs YAG/CO2Size

Common 5U 19” Rack format

Performance Power Stability & Linearity Modulation & Control RangeBeam Quality


Total Cost of OwnershipNo scheduled maintenance intervalEnergy Efficiency

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Performance : Beam QualityPerformance : Beam Quality

Application: Ceramic scribingFibre Laser λ=1.07um, M2<1.1

M2 < 1.1

200W Fibre Laser

CO2 Laser λ=10.6um, M2~1.3


400W CO2 Laser

Total cost of ownershipTotal cost of ownership

Fibre Lasers vs YAG LasersFibre Laser Lamp pumped YAG

Diode Pumped YAG

Scheduled Maintenance Interval

None 500-1000 Hours ( Lamp Pumped)10,000 Hours ( Diode Pumped ) Optical path requires frequent adjustmentRegular replacement of flashlampsPeriodic maintenance/ replacement of diode packs Diode pack maintenanceCleaning replacement and alignments of lenses and mirrors

C bl i $ 00 200 h


Consumable items None Lamps : $100-200 each Diode Packs : $5000-12000 each (Note: average costs)

Power Consumption Single phase 15-20% WPE

Single/3Phase 2-10% WPE

Chiller Not required for < 200W Cost $4000-$8000Replacement period ~ 24months

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Output power stability Output power stability

200W Laser over full operating temperature range 10-40˚C

314539-SP-200C-0004 Active Cycle Started 11 March 2008 18:29:25 Ended 12 March 2008 01:59:25

195

200

205

210

Pow

er (W

)

15

20

25

30

35

40

45

Tem

p (°

C)

Pow er_(W) Set_Temp Act_Temp Delta Power = 0.40W (± 0.1 %)


190

195

0 1 2 3 4 5 6 7

Time (hrs)

P

5

10

15 T

Pulse to pulse stabilityPulse to pulse stability

Pulse Energy Distribution for 10Hz, 50msec pulses at 100W

708090

010203040506070

4.81 4.82 4.83 4.85 4.86 4.87 4.89 4.90 4.91 4.93

Pulse Energy (mJ)

No.

Pul

ses

Min 4.832J

Max 4.882J

Sigma 0.007J

Avg 4.857J


68.26% of all pulses are within ±0.007J of 4.857J (0.15%)95.46% of all pulses are within ±0.014J of 4.857J (0.31%)99.73% of all pulses are within ±0.021J of 4.857J (0.46%)

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High modulation rateHigh modulation rate

200W Laser at 100kHz, 50% Duty cycle

Pulse shape of 200W laser at frequency of 100kHz and 50% duty cycle

0.10

0.15

0.20

0.25

0.30

0.35

Sign

al (a

rb)

Trigger

Signal


-0.05

0.00

0.05

0 2 4 6 8 10 12 14 16 18 20

Time (us)

Medical ApplicationsMedical Applications

Materials processingCuttingWeldingRapid PrototypingMarking

TherapeuticM di l A th ti


Medical Aesthetics

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Fine tube CuttingFine tube Cutting

Wide range of tubes and needles used in medical applicationsmedical applicationsPredominantly stainless steel but can be other metalsFine features required

h


High part accuracyNo burrs

Micromachining Micromachining Thin metal sheet and tube cuttingThin metal sheet and tube cutting

High beam quality allows very fine kerf as lowas 10um widths to be achieved for thin materials Cutting speeds with conventional solid state lasers are limited

Cutting highly detailed Coronary Stents


Cutting speeds with conventional solid state lasers are limited by repetition rates of a few kHz The direct modulation capability up to 100kHz of SPI’s CW-M fibre lasers allows high speed cutting process developmentProductivity improvements >5x in cutting speeds have been demonstrated by fibre lasers in these applications

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Growing use of laser welding in Growing use of laser welding in medical device manufacturemedical device manufacture

Laser welding providesHigh quality jointsR t bl Repeatable processHigh accuracyHigh reliabilityProcess that is in controlAbility to weld small and thin partsAbility to weld wide range of metallic materials


Ability to weld wide range of metallic materialsWelding of dissimilar materials

Traditionally Nd:YAG systems were used but now the Fibre laser is becoming the laser of choice

Comparable Nd:YAG weldComparable Nd:YAG weld

C l l thCan clearly see the overlapping spot welds in this pulsed seam weldTypical pulsed YAG weld in stainless steel


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Micro Welding of tubesMicro Welding of tubes

Material: 304 SS Laser Power: 90 60 30 W


Material: 304 SS

Speed: 3.5m/min (140”/min)

Focal length: 100 mm

Cover gas: Argon

Laser Power: 90, 60, 30 W

Tube diameter: 1.5 mm

Wall thickness: 0.4 mm

Bead on plate, fully penetrating

Welding Brachytherapy seedsWelding Brachytherapy seeds

35W power, 3s welding durationTube length used for rounded end: ~1.2 mm

Welding Brachytherapy SeedsSPI Lasers’ 100W Fiber Laser


Material – TitaniumShield gas - Argon

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Welding guide wire components Welding guide wire components

MaterialStainless Steel

Material thicknessMaterial thickness2.2 mm

Laser Power60 W

Cover gasArgon


Focal length lens100 mm

Weld speed time20 ms

Thin sheet weldingThin sheet welding

Material: Stainless SteelThi k (b h Thickness (both sheets): 25 mmPower: 30 WSpot diameter: 50 µmWeld time: 3 ms

200 μm


Weld time: 3 msWeld method: Trepanning

200 μm

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Butt welding of fine wiresButt welding of fine wires

Material: TungstenDiameter: 75 μmPower: 20 WSpot size: 50 μmPulse length: 1 msCover gas: Argon


Butt welding of fine wiresButt welding of fine wires

Material: NitinolDiameter: 0.26 mmPower: 45 WOptics: 120 mm focusing lens, no beam expanderSpot size: 60 μm


μPulse length: 20 msCover gas: Argon

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Wire BallingWire Balling

In medical applications numerous wires are numerous wires are used for insertion..No sharp edges can be toleratedHitting the end of cut

i i h l i 0.33mm diameter

l ti i lt d


wire with laser gives round ball end with no sharp edges

platinum wire meltedSPI 70W Air Cooled laser

Endoscope weldingEndoscope welding

Material: SS 1.4301Power: 50 WWeld speed: 50 mm/secWeld speed: 50 mm/secPart Diameter: 1.4 mmWall thickness: 0.1 mmBeam radius: 30 µm

Not to be distributed without prior consent of SPI Lasers plcCourtesy of Fraunhofer Institute for Laser Technology

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Rapid PrototypingRapid Prototyping

x-y Scanner Laser

Laser BeamLevelling System

Window

Metal PowderPart Part

Laser Beam


Retractable Platform

Powder

Courtesy of MCP-HEK

Example Example ““MainstreamMainstream”” Application Application for Generative Microprocessing / Manufacturingfor Generative Microprocessing / Manufacturing

Dental Caps!Dental Caps!


Images courtesy of MCP-HEK

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Plastic WeldingPlastic Welding


Plastic Welding of medical equipmentExample: Catheter kit and syringe welding

Fiber laser can give greater precision and finer spot size than DL

Medical markingMedical marking

Diverse number of applications

D t t iData matrixGraduationsPart numbersMarketing

Wide range of materialsS ifi i t


Specific requirementsOperating instruments need to go through sterilisation

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Medical AestheticsMedical Aesthetics

Wrinkle removalC t l d lCompact laser module1550nm


SPI’s Application facilitySPI’s Application facility

SPI has a dedicated technical facility in Santa Clara to support customer applications

Our staff have over 50 years of combined laser materials processing experienceCustomer samples are processed FOC on a case basis for a “proof of principle” More detailed process development is undertaken on a commercial basis


SPI offer a 30-day free evaluation laserOur on-site equipment includes commercially available systems

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SummarySummary

Fiber lasers are an alternative source for many medical related device manufacturing applicationsapplicationsFiber lasers

Low costNo maintenanceCompactHigh quality


Helping medical industry to:Reduce costsImprove quality

Thank You – Questions?


Fiber Lasers for Medical Applications · Rtbl Repeatable process High accuracy High reliability...

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