Metamorpha

The project will develop an ultrashort pulse micromachining system based on a combination of two spatial light modulators (SLMs) with an integrated galvo scanner to enable sophisticated digital beam shaping and steering from a single fully digital module. This will allow a single system to perform a variety of manufacturing processes (e.g. polishing, milling, drilling and cutting) which currently require different laser machines, mechanical and/or (electro-) chemical processes. A single METAMORPHA laser machine could replace a process chain of several steps that are currently achieved using environmentally damaging non-laser processes. A key aspect of the project is the development of made-to-measure laser processes. Each workpiece is scanned using a high resolution 3D surface topography quality sensor before processing. Using a machine learning based algorithm, a precision individualised laser micromachining process will be calculated so that every process is tailored to each workpiece to account for tiny variations in geometry or surface topography. During processing, real-time sensors monitor the processing zone to provide real-time feedback for system control. This allows the fine tuning of the machining procedure to account for the unpredictable variations between process runs.