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This study introduces a novel single-lens auto-focusing method for laser processing. It achieves high-speed surface detection and Z-axis adjustment simultaneously, overcoming previous speed limitations in advanced manufacturing.

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Area of Science:

  • Optics and Photonics
  • Advanced Manufacturing
  • Precision Engineering

Background:

  • Traditional laser processing auto-focusing relies on separate, slow surface detection and Z-axis adjustment modules.
  • Mechanical Z-axis stages limit processing speed, creating a bottleneck in high-throughput manufacturing.
  • Existing methods struggle to keep pace with rapid lateral processing speeds.

Purpose of the Study:

  • To develop a faster, integrated auto-focusing system for laser processing.
  • To enable quasi-simultaneous surface detection and Z-axis adjustment.
  • To accelerate advanced manufacturing processes requiring precise 3D positioning.

Main Methods:

  • A novel single-lens approach utilizing a high-speed Z-scanning optical element in a dual-beam setup.
  • In situ surface detection via a probing beam scanning the surface and confocal optics detection.
  • Dynamic surface detection achieved at 140-350 kHz, with focus control synchronized to the scanning lens oscillation.

Main Results:

  • Demonstrated dynamic surface detection with a controlled range, high repeatability, and linearity error as low as 1.10%.
  • Achieved quasi-simultaneous surface tracking and focus control at 140-350 kHz.
  • Significantly reduced axial alignment time compared to conventional methods.

Conclusions:

  • The developed single-lens approach overcomes the speed bottleneck in laser processing auto-focusing.
  • This method enables instantaneous surface tracking and precise focal alignment.
  • The approach holds significant potential for enhancing the speed and efficiency of 3D advanced manufacturing.