Aerotech's Innovative Motion Control Solutions at Laser World 2025

Photonics applications Precise positioning systems and optimised laser drilling solutions

2025-05-05 Source: Aerotech 3 min Reading Time

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At the Munich trade fair Laser World, Aerotech showcases cutting-edge motion control innovations — from high-speed laser drilling with the Aeroscript Plus Drill Optimizer to nanopositioning and dynamic gantry systems, all powered by the latest Automation1 platform.

The integrated Laserturn 160 linear rotation system was specially developed for cylindrical laser processing applications in high-throughput medical technology applications. The high-throughput system with directly driven linear and rotary movement combines automated material handling with laser wet cutting.(Source: Aerotech) — The integrated Laserturn 160 linear rotation system was specially developed for cylindrical laser processing applications in high-throughput medical technology applications. The high-throughput system with directly driven linear and rotary movement combines automated material handling with laser wet cutting.
(Source: Aerotech)

At Laser World of Photonics 2025 in Munich, Aerotech will be presenting its latest developments for motion control. Visitors can expect an insight into high-performance demo systems, including high-precision positioning solutions and the Aeroscript Plus Drill Optimizer, which enables efficient and profile-specific optimisation of laser drilling.

The focus will be on solutions for laser micromachining, optical measurement processes and high-precision positioning tasks.

The Aeroscript Plus Drill Optimizer function, which is available in the Automation1-iSMC control configuration, enables profile-specific optimisation of the motion path and motion parameters for drilling vias with Aerotech’s AGV Galvo scanners. Several thousand to several million holes can be drilled efficiently.

The two-stage optimisation process of the Drill Optimizer first calculates the shortest movement path for the AGV galvo laser scan head (AGV-HPO and AGV-XPO). The drive and scan head motors are then adjusted so that all movements take place within defined quality criteria. This allows the performance of the laser scanning systems to be maximised with minimal set-up effort.

The Drill Optimizer is available both as a stand-alone user interface in Automation1 Studio and as a .NET DLL. This enables seamless integration into the HMI (Human Machine Interface) of the respective machine control system.

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From the control software to the controller to the hardware: Aerotech supplies complete solutions for optical alignment and adjustment from a single source, such as the FibermaxHP photonics alignment platform for optoelectronics, including Automation1 control software.(Source: Aerotech)

Dynamic gantry control with high flexibility. The demo impressively illustrates the possibilities of gantry control — especially with the aggressive high-speed movements that make the system a real eye-catcher at the trade fair.(Source: Aerotech)

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LaserTurn 160: Optimised rotation and linear movement

The second generation of the Laserturn 160 platform will also be presented at the stand — a powerful solution for the high-precision machining of cylindrical workpieces, particularly used in medical device manufacturing. The system combines directly driven linear and rotary axis with optimised material handling and enables, among other things, laser wet cutting. In addition to the proven CCS130 configuration, an optional cable management system (CMS) is now available to simplify handling. The new ASR1300 rotation upgrade also increases throughput and expands the processing capacity for workpieces up to 4 mm in diameter.

Fiber Max: Nanopositioning at the highest level

The Fiber Max 3-axis system with ANT stages (XYZ) and a HEX150-140HL enables precise nanopositioning for photonics applications. At the trade fair, a live demo will show how the system uses special routines to achieve fibre alignment with maximum accuracy. While the ANT stages take over the arrangement of the fibres, the HEX150-140HL takes care of the angular alignment and the blind move function — i.e. the ability to return exactly to the original position after a long movement.

The high-precision mechanics are coupled with the Automation1 control platform, which enables low-latency motion control and optical alignment algorithms. This allows all automation processes to be programmed via a central control interface.

Gantry demo: Dynamic portal control with high flexibility

Aerotech is also presenting a high-performance gantry system that has been specially developed for highly dynamic motion sequences. The design is based on Pro-LM tables, supplemented by an ADRS drive on the bridge. Flex cable management improves cable routing, while swivel joints between the uprights and the bridge enable easy rotation around the vertical axis. The demo impressively illustrates the possibilities of gantry control - especially with the aggressive high-speed movements that make the system a real eye-catcher at the trade fair.

Automation1 2.10: New functions for maximum control

The latest release 2.10 of the Automation1 motion control platform offers enhanced control functions for greater precision and safety. The new features include:

Dynamic plot display with conditional signal colour and visibility adjustment

Improved access control and secure communication for drive controls

20 kHz laser control for high-resolution servo axes

Advanced galvo calibration for more precise marking and measurement

Optimised fine-tuning with current loop feedforward for higher bandwidth

Further improvements: Updated documentation, PWM optimisation, API enhancements (.NET & Linux)

IGM positioning systems: More rigidity and dynamics

Last but not least, Aerotech is presenting a powerful IGM positioning system that, in combination with an AGV-20HP laser scanning head, increases scanning speed and improves throughput. The IFOV (Infinite Field of View) function synchronises servo axes and laser scanners to reduce errors and stitching effects and increase machining accuracy.

“By combining granite with specifically selected bearing types, our IGM positioning tables enable a particularly rigid design,” explains Simon Smith. “This design ensures maximum stability and precision and can be flexibly adapted to individual customer requirements.”

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