Use of Laser Technologies
Mundt and Associates provide laser systems for the following industires:
Laser cutting is a technique that is commonly used for industrial applications. It is an established process with a lot of flexibility. It is a non-contact process that produces parts right from the tool. Laser cutting is very precise with excellent dimensional stability, a very small heat affected zone and can cut with narrow kerfs.
Laser cutting works by focusing the laser output, usually computer controlled, on the material to be cut. The material being cut is either melted, burnt, vaporized or blown away by a jet of gas which leaves a clean edge with a high-quality surface finish. Mundt & Associates, Inc. provides equipment for high precision laser cutting used by the medical, aerospace and other industries that have exacting needs and processes.
These laser types are all similar, using light to process material, yet differ in their application use. The cut geometry, cycle time, system technology and material composition are all crucial factors in the decision of which laser is best suited for a specific task.
Laser cutting, compared to conventional machining, allows for fast configuration changes, is far more cost effective because of lowered consumables, and is applicable to both small and large batch production. The benefit of laser cutting is that it provides small kerf widths, high feed rate and minimal heat input with complete accuracy.
Several types of lasers can be used for cutting:
- CO2 Laser
- Nd-YAG Laser
- Fiber Laser
- Pulsed Laser
- Ultra Short Pulse Laser
There are many kinds of metals and a variety of other materials that can be laser cut, a few examples are:
- Carbon Steel
- Ferrous Metals
- Mild Steel
- Non-Ferrous Heavy Metal
- Precious Metals
- Stainless Steel
Benefits of laser cutting:
- Cuts Any Shape
- Produces Small Kerf Widths
- Cutting Tools Do Not Dull
- Cuts High Precision Small Parts
- Cost Savings (due to less waste of material consumables)
We use laser scribing and mechanical scribing for thin film solar cell fabrication. The important factor to recognize is that tools can be used to do ceramic processing, and laser based tools enable production steps to be done in a non-contact manner.
Laser or mechanical scribing is a technique for isolating the active layer. It avoids the use of chemicals, lowers the risk of damage to the panel and can be integrated into a continuous work flow. It is also fast and flexible enough to allow higher throughput. High accuracy is important for thin film cells because the size and location of the scribe line contributes to cell surface area and efficiency.
Lasers are preferred due to the high precision and quality of ablating thin layers of material without damaging nearby layers or the material around the scribe line. High volume production of panels using a streamlined laser scribing process is faster and more reliable than mechanical scribing
- Maximize Yield Levels In Solar Fabs
- Increase Production Line Throughput
- Laser Based Tools Offer High-Speed Material Processing Via Automated, Inline Horizontal Substrate Handling
- Reduces Manufacturing Costs
- Increases Final Panel Efficiency
Laser welding is a technique used for joining two materials with precisely controlled penetrations and the utilization of high speed with accuracy. Process speed is dependent on the selected material, the laser type and the power chosen to complete a particular process. A large variety of materials of differing thicknesses can be welded by various methods. Usually, those metals that are welded by conventional technology can also be laser welded. Some polymers are welded using a different wave-length to accommodate the material.
As the sophisticated industrial market grows, needs become more complex so laser- processing techniques must expand to enable the manufacture of highly precise components at an extreme level of speed with accuracy. Mundt & Associates has the technology to provide accuracies in nanometers, from the production of a prototype through an entire production run. The company has the capability to process products from simple two-dimensional parts through to the most complex parts using multi axes machining.
Classic materials for conventional welding also lend themselves to laser welding to achieve, when necessary, high speeds, accuracy and controlled penetration. Advantages to using laser welding as opposed to conventional welding are:
RESISTANCE WELDING versus LASER WELDINGThe laser weld provides high precision controlled weld depth penetration. The weld probes do not get dirty and there is no contact with the part.
ULTRA SONIC WELDING versus LASER WELDINGThe parts do not need to be rigidly mounted and there is no contact force.
TIG or MIG WELDERS versus LASER WELDINGLaser welds provide very narrow weld widths, controlled penetration, less heat input, higher processing speeds and lower distortion.
Product applications include:
- Electronic Components
- Engineering Parts
- Implantable Medical Devices
- Machine Construction and Repair
- Micro Welding
- Miscellaneous Medical Devices
- Mold and Tool Construction and Repair
- Precision Spot Welding
- Thin Sheet and Precious Steel Production
- Turbine Parts
Advantages of laser welding compared to conventional welding:
- Contact-Free Processing with No Electrode Wear
- Diverse Materials with Different Thickness are Weldable
- Easily Converts to Automatic Operation
- High Flexibility with Process and Geometry
- High Reliability with Maximum Flexibility
- High Welding Speeds
- High Weld Seam Quality
- Lower Heat Input
- Simultaneous Operation at Different Machines
- Small weld profiles
Laser ablation is an a-thermal process for removing material from a solid surface by irradiating it with one of the multiple commonly used lasers today. Laser energy is absorbed by the material that causes it to vaporize. The amount of material that is removed by a single pulse depends upon the material properties, laser wave-length and pulse energy.
Laser pulse widths used can vary over a wide range of duration and are typically measured in picoseconds, femtoseconds or attoseconds. Laser ablation is ideal for multiple industrial applications that require high accuracy or low heat input for material processing. No solvents are used so the process is environmentally friendly for the operator who is not exposed to chemicals.
Laser bonding can improve your product performance, yield and reliability. The Mundt IB-1284 laser bonder produces welds with controllable bond area and depth. Ultrasonic wire bonds only interact with the terminal to a depth of some few angstroms. Latent failure of ultrasonic wire bonds (diffusion and/or contamination) is well known and can take years to develop. The laser bond process permits control of the area and depth of the bond geometry and also the selection of materials with high thermal stability to provide a more robust and reliable connection.
FIGURE 1: Shows an SEM images of a laser bond with about 800nm of weld penetration.
Laser Ribbon Bond (LRB) cross section showing precise penetration control
FIGURE 2: Shows the side-by-side results of fatigue tests done on the ultrasonic wirebonds vs. laser bonds. The results shown of this test demonstrate the fatigue life of the laser bond that interconnects is several orders of magnitude better than comparable ultrasonic aluminum wirebonds.
Benefits of Laser Bonding:
- Bonder reliability has been improved with the laser bond.
- Bond forces are lower to minimize damage to fragile components.
- Non-rigid or flexible pads can be bonded more easily with laser bonds.
- Vibration-sensitive components can easily be laser bonded.
- A wider range of materials can be used with laser bonding.
- The entire device does not need to be heated to utilize laser bonding.