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Product category: Software, off-line programming, CAM, for metal cutting machine tools
News Release from: Delcam | Subject: PowerMill CAM at Oxford Lasers
Edited by the Manufacturingtalk Editorial Team on 30 April 2008

Milling CAM programs laser
micro-machining

Delcam reported that Oxford Lasers is using PowerMill CAM to program 3D laser micro-milling processes, the Z-axis being the laser system lens vertical movement.

Delcam reported that Oxford Lasers is using PowerMill CAM to program the company's range of laser-based micro-machining systems After many years' success with 3-axis systems, Oxford Lasers is now producing 5-axis equipment

Project leader responsible for micro-machining systems and applications at Oxford Lasers, Dr Dimitris Karnakis, said that micro-machining with lasers offers distinct advantages over conventional machining technology.

He believed that, comparatively, lasers can machine very quickly, more accurately and give a better surface finish.

Using lasers avoids the problems associated with producing cutting tools that are small and robust enough to cut shapes at the micron level.

Dr Karnakis said that lasers can produce the smallest shapes more effectively when compared with using EDM.

* Laser milling - when milling using a laser, the programming in the X- and Y-axis is the same as for a normal milling machine.

The difference is that with laser milling, a lens moves in Z-axis to determine the width of the beam and, therefore, the position and depth of the cut.

The depth of cut is also a function of the power of the laser and the material being processed.

Following success with its 3-axis equipment, Oxford Lasers has moved into 5-axis operation.

The extra axes the tilting and rotation of the part.

The company told manufacturingtalk that this approach allows optimisation of the Ra surface roughness.

Ra values well below 1 micron are achieved by running different passes of the laser over the surface at different angles.

It also produces undercuts.

Oxford Lasers said that this is generally accepted to be difficult with lasers because a laser on a 3-axis machine cannot cut a truly vertical wall because of the inherent angle in the beam.

Dr Karnakis said: "We had problems with our existing software as soon as we tried to move to 5-axis operation; our customer suggested that we should contact Delcam and we have never looked back.

We have been very satisfied, not just with the software but also with the supporting services, especially the knowledge and timely response of the staff on the help desk".

* 5-axis laser milling applications - several of the 5-axis applications originate from university research departments.

For example, a team at Aston University in Birmingham, UK, is using a system from Oxford Lasers programmed with PowerMILL to machine very narrow, high-aspect-ratio cavities into 125 micron diameter optical fibres to allow manufacturing of fully integrated in-line photonic devices for real-time sensing.

Such in-line devices will be available from FiberLogix.

Laser machining these cavities offers a more flexible, precise and fast method compared to lengthy mechanical polishing methods and without the risk of permanent mechanical failure.

PowerMILL enables the production of complex 3D structures on a scale of a few microns, adding a new dimension to the design of photonic devices, said Delcam.

It has now become possible to manufacture an entirely new family of devices with many applications over a wide area.

In another example, PowerMILL is used to laser machine microfluidic devices for biochemical analysis.

These will allow biomedical researchers to manipulate fluids in networks of channels and monitor reactions requiring only small volume of samples and reagents, producing little waste and offering rapid analysis times at relatively low cost.

* About Oxford Lasers - Oxford Lasers was founded following pioneering laser research at Oxford University.

Over the past 30 years, it has become established as one of the world's leading laser manufacturers.

During that time, the company has focussed on two application areas.

1 - Laser micromachining.

2 - High-speed imaging.

The company is a world leader in using lasers for micro-drilling, which is used, for example, to form high-precision fuel injectors for automotive engines.

It also runs its own manufacturing operation using its own lasers, mainly to demonstrate and prototype the systems to potential buyers.

More recently, the company has moved into laser micro-milling. Request a free brochure from Delcam ...

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