With the AGV3D, Aerotech, manufacturer of high-performance motion control and positioning systems, launches a new 3-dimensional beam deflection system for laser micromachining. According to Aerotech, the 3D laser scanner with high thermal stability is particularly suitable for the high-precision manufacture of complex components for applications in the medical field, microelectronics, the automotive industry, and now also in additive manufacturing. Easy-to-use functions simplify integration into a machine, system or subsystem.
3D laser scanner heads are particularly suitable for applications where flat-panel lenses (f-? lenses) cannot be used, or where the contour of a workpiece requires adaptation of the focusing distance in z-direction. Most 3D scanners on the market to date use a third rotating galvometric motor with a tangential arm to track the focusing optics. However, these designs tend to become thermally unstable. This limits dynamism and accuracy in continuous operation, which is becoming the norm for all industries and applications.
"With our AGV3D system, we offer a fast, flexible and highly accurate laser scanner solution, which linearly positions the focusing optics thanks to a direct-drive linear system, with a very high-resolution position encoder."explains Simon Smith, Aerotech's European Director. Positioning errors are considerably minimized by the high rigidity and precision of the linear module known as DFM (Dynamic Focusing Moduledynamic focusing module). "As the only scanner on the market with a DFM that relies on a high-performance linear motor and direct-drive focusing axis, the AGV3D offers superior dynamic performance with controlled motion for precise, reproducible focusing."continues Simon Smith.
Versatility and efficiency in the manufacturing process
Thanks to water and air cooling, the new scanner guarantees maximum thermal stability. Temperature gradients within the AGV3D are avoided, reducing errors caused by thermal drift. This ensures stable performance throughout the entire machining time, with highly consistent and repeatable laser machining precision.
"Thanks to this innovation, the AGV3D achieves the highest productivity of any 3D scanner currently available - and for a multitude of different laser wavelengths."says Simon Smith. This makes for versatility and efficiency in the manufacturing process, and eliminates the need for manual focal length adjustments when the parts to be manufactured change.
In this way, the AGV3D enables you to maintain the right focal distance for the laser over the entire work volume, quickly and conveniently. Unlike other solutions, which require time-consuming manual DFM adjustments to accommodate changes in the workpiece, the AGV3D features two simple user-selectable configuration settings, covering fields of view from 100×100 mm up to 1000×1000 mm and beyond.
Optimized for industrial use
Thanks to the AGV3D's large field of view, it is also possible to use smaller, more efficient motion mechanisms for positioning the workpiece. Depending on the respective process requirements, the 3D scanner is available with different apertures for different beam diameters. On request, Aerotech can also supply the AGV3D fully configured, including lens. The use of the AGV3D is particularly relevant for applications where workpieces fluctuate in height and density, or for multi-layer additive manufacturing. If, in addition to a constant focusing diameter, an angle of incidence as perpendicular as possible is also important, the AGV3D can of course also be used with telecentric lenses.
Wide scope of application
In practice, the 3-axis laser scanner is therefore predestined for applications where 3D volumes have to be processed, the working distance has to be varied, or where a wider field of view than that of F-theta lenses has to be achieved. This may include, for example, the manufacture of medical products, but also, in general, additive manufacturing by selective 3D laser sintering, cylinder and tube machining, deep engraving, 3D laser micromachining and micro-structuring.
"As with all Aerotech products, our AGV3D is also designed for long life in production environments."explains Simon Smith. The scanner body is sealed and airtight, to protect the optical components from impurities and reduce the risk of damage.
One controller for all movements
The use of an Aerotech controller facilitates synchronization and coordination of the AGV3D's movement with the system's other motion axes, including servo and stepper motor-driven tables, piezoelectric nano-positioners and hexapods. Since all devices are programmed and controlled via the same user interface, ease of use is seamless and intuitive.
Synchronization with other motion axes also gives the AGV3D the special capability of being able to process workpieces that are larger than its field of view, but still retain their high machining quality in the process. The proven IFOV function (infinite field of view) is available to avoid discontinuities and connections. With this, linear or rotary axes are synchronized with the laser scanner, theoretically extending the scanner's field of view to infinity.
The PSO function (Position Synchronized Output - Aerotech's position-synchronized output) synchronizes an output to position and triggers the laser hyper-precisely on the trajectory. This output can also be used for data acquisition, perfectly synchronized with the position on the trajectory. In addition, an analysis is made to take account of triggering delay, or acceleration phases are anticipated to limit triggering errors.