Made-to-measure micromachining with laser beams tailored in amplitude and phase

"The METAMORPHA concept is a single agile USP laser micromachining platform to replace many conventional manufacturing process chains. It has the potential to eliminate thousands of environmentally damaging production processes. METAMORPHA is all-electric, all-digital, produces no waste chemicals and enables novel processes for product rework and repair.

All-in-one module: The key to this agility is a combination of two cascaded spatial light modulators (SLM) and a galvo scanner resulting in the most sophisticated beam shaping and steering ever developed. This allows a single module to perform the job of several laser processing heads: e.g. polishing, milling, drilling and cutting (importantly including any wall angle).

Made-to-measure laser processes: Each infeed component is scanned with a high resolution 3D sensor. A machine learning algorithm determines an individualised laser process to maximise efficiency and ensure ""first time right"".

In-line process control: Data from additional online sensors are processed using an edge device running a self-learning algorithm to provide real-time feedback for system control. The ultra-fast edge-based signal processing and synchronisation are key project topics.

Agile and scalable: Suitable for any standard industrial production line including 2-, 3- or 5-axis, rotating and roll-to-roll, and for scale up to parallel processing with multiple modules. The three end use cases (UCs) show the versatility and scope for replacing existing process chains:

UC-1 PHILIPS: Small complex metal parts (shaving heads) requiring 90 degree wall angles.

UC-2 TKSE: Large area embossing rollers and the re-writing of old rollers.

UC-3 CERAT: Very hard carbide parts and refurbishment of worn parts.

Sustainability assessment: A life cycle analysis (LCA) and social LCA will be carried out to quantify the environmental and socioeconomic benefits. A detailed plan for exploitation and an extensive dissemination and communication plan are in place."