Micromachining Aerotech’s new high-precision laser scanner delivers sub-micrometre accuracy

Related Vendors

Aerotech GmbH

AMETEK GmbH Division Creaform Deutschland

Meusburger Georg GmbH & Co. KG

Renishaw plc

Aerotech introduces the AGV5D, a cutting-edge 5-axis laser precession scanner designed for high-precision laser micromachining. By integrating advanced control technology and innovative thermal management, the AGV5D enables the creation of complex geometries with sub-micrometre accuracy.

The motion control experts at Aerotech present the AGV5D, an innovative 5-axis laser precession scanner specially developed for laser micromachining. The combination of scanner and 5-axis laser motion system makes it possible to create high-precision bores, contoured slots and other complex geometries with dimensional tolerances in the sub-micrometre range. According to Simon Smith, European Director at Aerotech, the special design significantly minimizes thermal drift during the machining process — a crucial aspect for long-term accuracy.

By combining precise linear motion axes and advanced control technology, the AGV5D offers complete control over the entire micromachining process, including laser, scan head and workpiece positioning. This G-code based approach enables the integration of standard CAM software, significantly expanding the range of applications.

The AGV5D works in a similar way to a 5-axis CNC machining center, but uses the advantages of laser processing to ensure maximum precision and flexibility. By utilizing a single control system, smooth coordination between the movements of the laser beam and workpiece positioning is achieved, ensuring a consistently high quality of machined parts and a simplified programming.

The AGV5D uses RS-274 compliant G-code commands to steer the laser beam along 2D and 3D paths such as lines and arcs. The beam is directed through a nozzle at the lowest point of the scan head so that the working volume in which the laser processing takes place is below this nozzle. The paths programmed for the X, Y, Z, A and C axes move the focussed point within this working volume. In addition to beam guidance in five degrees of freedom (DOF), the system also controls external X, Y and Z axes that position the workpiece under the scan head to extend the field of view and synchronize the movements with the beam path. Aerotech's Automation1 software-based machine control (iSMC) monitors the entire system and coordinates the G-code trajectories with the powerful Aeroscript programming commands.

The ability to optimize parameters and simulate movements in both the virtual controller and the real hardware provides users with precise insights into the executed movement sequences and the control of the laser pulses.

To ensure optimum thermal stability, the AGV5D contains no electronics in the scan head, which minimizes heat transfer and thermal drift. The actively water-cooled motors provide additional stability during longer machining operations. The scan head operates with sealing air to minimize dust ingress, while the scan mirrors and optics are cooled by direct gas purging. These measures improve the repeatability and reproducibility of the machining results, which leads to a consistently high quality of the manufactured parts.

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