Modular handheld laser material processing system with multi-axis beam movement

Abstract

A handheld laser tool system includes a handheld tool with a body portion having a forward laser beam discharge opening, a handgrip extending downwardly from a rearward end of the body portion. The handheld tool providing movement of the laser beam in a plurality of axes. A laser beam path in the handheld tool is defined by an internal optics system comprising a collimator, a two-axis wobble unit, a focusing lens, and a protective window. The two-axis wobble unit comprising a modular pair of stacked mirrored galvanometers with respective axes parallel and with a stationary mirror in the laser beam path positioned intermediate two oscillating mirrors of the pair of galvanometers. The focusing lens movable axially in the laser beam path providing forward-rearward movement of a focal point of the laser beam.

Description

Attorney Docket No. 5117.0024W01MODULAR HANDHELD LASER MATERIAL PROCESSING SYSTEM WITHMULTI-AXIS BEAM MOVEMENTFIELD OF INVENTION

[0001] The present disclosure relates to handheld laser systems, and more particularly to a modular laser system with a handheld laser tool for material processing having interchangeable components and programmable features for improved functionality and user experience.BACKGROUND

[0002] Handheld laser material processing systems, particularly handheld laser welding tools, have gained popularity in recent years due to their portability, precision, and ability to perform high-quality welds in various applications. These systems typically consist of a portable laser radiation generation and control unit, a handheld laser tool, sometimes referred to as a “torch,” and connecting cabling between the handheld laser tool and the laser power and control unit. As laser technology has advanced, the average power of laser diodes has increased while their cost per watt has decreased, making higher-power laser systems more accessible to smaller machine shops and individual users.

[0003] Traditional laser welding equipment often requires large, stationary equipment. that limits flexibility in welding operations, particularly on complex or bulky workpieces. Handheld laser welding systems address this limitation by providing a more compact and mobile solution. Due to limitations in size and complexities, capabilities available in stationary laser equipment have not been practical in handheld laser tools. One such capability that has been challenging to add to handheld laser tools is multiple axis beam movement.

[0004] SUMMARY

[0005] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0006] As the cost of laser radiation generation has decreased and handheld laser processing tools have become less expensive, the inventors have recognized opportunities for integrating improved functionality, efficiencies, and modularities into handheld laser tools thatAttorney Docket No. 5117.0024W01 enhance the user experience, facilitate safe practices, and provide for improved material processing results, particularly associated with handheld laser welding.

[0007] A conventional stationary laser material processing system, particularly a laser welding system, utilizes a laser beam with a focal point for performing laser operations that oscillates in a single axis or two axes. The back-and-forth oscillations may be termed a wobble. A single axis wobble may be accomplished with a conventional mirrored galvanometer with motor shaft connecting to a mirror with a plane of reflective surface of the mirror coextensive with the axis of the reciprocating shaft. Single axis wobbling have been incorporated into handheld laser tools.

[0008] Two axis wobbling unit typically requires two mirrored galvanometers with the shaft axis arranged at 90 degrees and may include other mirrors and lenses, resulting in a bulky and unwieldy optics system that is suitable for stationary laser material processing systems but very unsuitable for handheld laser tools.

[0009] In embodiments of the invention, an optical system providing a two-axis wobble utilizes two mirrored galvanometers arranged in a stacked configuration that readily fits within the size constraints of a handheld laser tool. In embodiments the optical system with two mirrored galvanometers may be contained in a handheld laser tool having a width of less than 3 inches. In embodiments the optical system with two mirrored galvanometers may be contained in a handheld laser tool having a width of less than 2.5 inches. In embodiments the optical system with two mirrored galvanometers may be contained in a handheld laser tool having a width of less than 2.0 inches.

[0010] A feature and advantage of embodiments is a two axis wobble unit fits in a conventionally sized handheld laser tool.

[0011] A feature and advantage of embodiments is that the focal plane and also focal point of a handheld laser tool may also be moved and / or adjusted in a direction along the axis of the laser beam by moving a focus lens axially within the handheld laser tool by a motor and linear translation mechanism. A feature and advantage of embodiments is a conventionally sized handheld laser tool with a multiple axis movement of the laser beam with respect to the tool.

[0012] A feature and advantage of embodiments is a handheld laser tool that has a rearward receiving region for a wobble unit having a form factor and both a single axis wobble unit having a single mirrored galvanometer and a two axis wobble unit with two galvanometers are both readily sized and configured with said form factor such that a single axis wobble unit may be swapped out for a two axis wobble unit, or vice versa, or wobble units with different operating characteristics may be installed in the receiving region. In embodiments, a handheldAttorney Docket No. 5117.0024W01 laser tool with a rearward receiving region may receive and operate with any one of a) a nonwobble module, b) a single axis wobble unit, and c) a dual axis wobble unit.

[0013] According to another aspect of the present disclosure is that a two axis wobble unit is provided in a handheld laser tool a]having a forward laser discharge opening and a downwardly extending handgrip by first reflecting a collimated laser beam that is projecting upwardly in an interior of the handgrip with an oscillating mirror, mirror changing the direction of the laser beam to be more rearwardly and more laterally to strike a stationary mirror positioned in the interior of the handheld laser tool on an interior side of the handheld laser tool, and then reflecting the beam from the stationary mirror rearwardly to strike a forward facing mirror surface on an oscillating mirror that oscillates about an axis extending forwardly and rearwardly in the handheld laser tool, the forward facing mirror then directing the laser beam to a focusing lens forward in the handheld laser tool.

[0014] According to another aspect of the present disclosure, a handheld laser tool is provided. The handheld laser tool includes a compact, handheld laser tool having the configuration of a handgun with a body portion having a forward laser discharge opening, a handgrip portion, a trigger actuation. In embodiments, the handheld laser tool has two axes of laser beam wobbling, allowing for any shape to be projected onto the work piece surface.

[0015] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0016] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0017] FIG. 1 is a conceptual view of a handheld laser welding system and a work piece.

[0018] FIG. 2 is a conceptual perspective view of the handheld laser tool FIG. 1 performing a weld on the workpiece.

[0019] FIG. 3 is a close up conceptual view of a laser beam focal point and the movability of the focal point with respect to the handheld laser tool in the x-y-z axis.

[0020] FIG. 4A is conceptual view of a handheld laser tool illustrating internal positioning of components of an optics system therein providing movement of the focal point of the laser beam in the z axis and the x axis.

[0021] FIG. 4B is conceptual view of a handheld laser tool illustrating internal positioning of the focus lens of an optics system utilizing a manually operable motion translationAttorney Docket No. 5117.0024W01 mechanism of the focus lens and providing an exteriorly viewable position indicator for movement of the focal point of the laser beam in the z axis.

[0022] FIG. 4C is conceptual view of a handheld laser tool illustrating internal positioning of the focus lens of the optics system utilizing a different motion mechanism and providing an exteriorly viewable position indicator for movement of the focal point of the laser beam in the z axis.

[0023] FIG. 5 is another conceptual view of a handheld laser tool illustrating positioning of components of an optics system therein having a dual wobble unit providing wobble of the laser beam in the x and y axis.

[0024] FIG. 6 is a top plan view of a handheld laser tool in accord with embodiments.

[0025] FIG. 7 is a side elevational view of a handheld laser tool in accord with embodiments

[0026] FIG. 8 is a front elevational view of a handheld laser tool in accord with embodiments.

[0027] FIG. 9 is an exploded view of the handheld laser tool of FIGS.6, 7, and 8.

[0028] FIG. 10 is a partial exploded perspective view of handheld laser tool with a receiving region for receiving a single axis wobble unit or a dual axis wobble unit in accord with embodiments.

[0029] FIG. 11 is a cross-sectional view of the handheld laser tool of FIG. 10 with the dual axis wobble unit inserted therein and showing the laser beam pathway for accomplishing the dual wobble function.

[0030] FIG. 12 is an exploded side view of components of the optics system of a handheld laser tool with a dual wobble function in a compact arrangement.

[0031] FIG. 13 is an exploded perspective view of the components of the optics system of a handheld laser tool with a dual wobble function in a compact arrangement.

[0032] FIG. 14 is an exploded plan perspective view of the components of the optics system of a handheld laser tool with a dual wobble function in a compact arrangement.

[0033] FIG. 15 is a perspective view of a dual wobble unit of FIGS. 9-14,

[0034] FIG. 16 is a partial exploded view of the mirrored galvanometers and bracket of the wobble unit of FIG. 15 separated from the bracket.

[0035] FIG. 17 is a partial exploded view of the mirrored galvanometers of FIG. 16.

[0036] FIGS. 18 is a perspective view of a single wobble unit of FIG. 10.

[0037] FIG. 19 is a partial exploded view of the mirrored galvanometer and bracket of the single wobble unit of FIG. 18.Attorney Docket No. 5117.0024W01DETAILED DESCRIPTION

[0038] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0039] The present disclosure provides a modular handheld laser system designed to enhance user experience and operational efficiency. Referring to FIGS. 1 and 2, a material processing laser system 100 has a laser power and control unit 104, a handheld laser tool 106, and an umbilical cord 108 connecting the two at a removable connection 110 at the handgrip portion 112 of the handheld laser tool. The handgrip portion 112 joins to a rearward end 113 of a body portion 114 with a forward laser discharge end 115. A nozzle 116 is removably attached at a coupling 118 at the forward discharge end 115. In embodiments, the laser power and control unit 104 may have a laser energy generation source 120, a controller 121, a coolant system 122, a process gas control system 123 and a user interface 124 in the form of controls, indicators, and / or a touchscreen, for example. Controls and processing for the functions described herein may also be provided directly on the handheld tool. The laser power and control unit may be connected to a process gas tank with valving in the power and control unit to control the process gas to the handheld tool. A workpiece 125 may be connected to the laser power and control unit by way of a conductive wire 126 such that a complete closed circuit is made with the nozzle contacting the work piece for assurance that the laser energy is directed toward the workpiece. Material processing laser systems are disclosed in U.S. Patents and Publications: US 2024 / 0261897, US 2024 / 0286220, US 2024 / 0009758, US 2024 / 0173755, and USP 11,364,572 owned by the owner of this application. Said patent and patent publications are incorporated by reference herein for all purposes.

[0040] In FIG. 2, the handheld laser tool 106, configured as a welder, is illustrated in an operational mode with laser beam 127 emitted from the laser discharge end 115 generating plasma 128 on the work piece 125 as a weld 130 is accomplished.

[0041] FIG. 3 illustrates an exemplary positioning of the focal point 129 of the laser beam and a x-y-z reference coordinate system depicting the respective movable positioning of a focal point 129 with respect to the handheld laser tool 106, more particularly the nozzle 116. FIGS. 6-8 also illustrate the reference coordinate system.

[0042] FIGS. 6-8 depict embodiments of a handheld laser tool with sizing that is consistent with conventional handheld laser tools. In embodiments, the length LI of the bodyAttorney Docket No. 5117.0024W01 portion including the nozzle may be in the range of 5 to 14 inches inclusively. In embodiments, the length LI of the body portion including the nozzle may be in the range of 6 to 12 inches inclusively. In embodiments, the length LI of the body portion including the nozzle may be in the range of 6.5 to 11.0 inches inclusively. In embodiments, the length L2 of the body portion without the nozzle may be in the range of 4 to 12 inches inclusively. In embodiments, the length L2 of the body portion without the nozzle may be in the range of 5.5 to 10.5 inches inclusively. In embodiments, the length L2 of the body portion without the nozzle may be in the range of 6.5 to 9.0 inches inclusively. In embodiments, the length L3 of the handgrip portion 112 without the nozzle may be in the range of 2.7 to 6.0 inches inclusively. In embodiments, the length L3 of the handgrip portion 112 without the nozzle may be in the range of 3.5 to 5.5 inches inclusively. In embodiments, the length L3 of the handgrip portion 112 without the nozzle may be in the range of 4.2 to 5.2 inches inclusively. In embodiments, the width W1 of the body portion may be in the range of 1.0 to 3.5 inches inclusively. In embodiments, the width W1 of the body portion including the nozzle may be in the range of 1.0 to 2.5 inches inclusively. In embodiments, the width W1 of the body portion including the nozzle may be in the range of 1.2 to 7 inches inclusively. In embodiments, the width W1 of the body portion including the nozzle may be less than 3.0 inches. In embodiments, the width W1 of the body portion including the nozzle may be less than 2.5 inches. In embodiments, the width W1 of the body portion including the nozzle may be less than 1.5 inches. In embodiments, the above measurements reference the dimensions of the exterior housing and do not include projecting switches, latches, or other items projecting from the exterior housing.

[0043] Referring to FIGS, 4, 10, 18, and 19, a handheld laser tool 132 has an optics system 134 that includes various optical components including a collimator lens 135, a single axis wobble unit 136 with a mirrored galvanometer 137 in a galvanometer bracket 138, a focusing lens 140, and a replaceable protective window 141. The single axis wobble unit 136 having an oscillating mirror 139 driven by a motor 142. The laser beam 143 follows the laser beam path 144 as defined by the optical components with the focusing lens 140 providing convergence of the laser beam 143 to converge at a focal point 129 on a focal plane at the forward end 145 of the nozzle 116. As depicted in FIGS. 10, 18, and 19, the single axis wobble unit may be modular by way of the bracket 138 that is configured to securely attach to the chassis 147 of the handheld laser tool 132. The module may be swapped out and replaced, for example, by a two-axis wobble unit.Attorney Docket No. 5117.0024W01

[0044] As illustrated in FIG. 4A, the focusing lens 140 may have a carriage 145 attached thereto to be axially movable, with respect to the axis al that is coincident with the laser beam path 144 of the body portion 114 of the handheld laser tool. The carriage with an internally threaded member 146, may be attached to a screw 148 constrained in bearings 149 that is rotatable by a motor 150. The axial movement 151 of the focusing lens 140 provides movement of the focal point 129 of the laser beam in the z direction. Such movement can be accomplished before the operation of the tool, or in instances during operation of the tool. Although the axially movable focusing lens is illustrated in a optical system of a handheld laser tool with a single axis wobble unit 138, it may also be utilized with handheld tools having an optical system with a dual axis wobble unit, as describe below, or optical systems with no wobble unit at all. Other known mechanisms may be utilized for axially moving the focusing lens 140.

[0045] Referring to FIG. 4B, a handheld laser tool 132 may have a manually exposed wheel 152 that engages a screw member 153, the screw member attached to a focus lens unit 154 to axially translate the position of the focus lens unit in the laser beam path 144. An indicator 155 may project through a slot in the housing to provide position indication of the focus lens unit.

[0046] Referring to FIG. 4C, a handheld laser tool 132 may have manually exposed stops 156, 157 for the range of linear motion of the focus lens unit 154. One stop may be a rotatable screw with an internal head 158 that may accessed from the exterior, for example through a hole, for position adjustment of the focus lens unit . The focus lens unit may have a position indicator 155. In other embodiments, similar mechanisms may be utilized to translate the collimating lens 135 or lens unit along the laser beam path 144 for adjusting the focal plane in the z axis.

[0047] Referring to FIG5. 9, 10, and 11, a handheld laser tool 160 with an optical system 162 having two axis wobble unit 164, is illustrated. The two-axis wobble unit 164 has a galvanometer bracket 165 for receiving two mirrored galvanometers and attachment of the bracket with galvanometers to the chassis of the handheld laser tool providing compact optical system by way of the mirrored galvanometers being stacked on top of one another and being aligned with their elongate axis extending forwardly and rearwardly within the handheld laser tool. Details of the bracket 165 are best shown in FIGS. 12-17.

[0048] The bracket 165 receives a lower first mirrored galvanometer 167 therein. The first mirrored galvanometer having a rearward motor 169, a motor shaft 171 extending from the motor and that connects to a mirror bracket 173 secured to an oscillating first mirror 175. The first mirror 175 has a laser beam reflective surface 176, that faces rearwardly, and with theAttorney Docket No. 5117.0024W01 motor providing the oscillation of the first mirror also positioned rearwardly of the first mirror. The first mirror 175 is mounted on the mirror bracket 173 having configuration that provides a laser beam window 174, rather than utilizing a conventional shaft extending along a shaft axis that would impede the laser beam being reflected off of the rearward facing mirror. In embodiments, the mirror bracket 173 has a U-shape. The motor shaft, bracket, and first mirror have a reciprocating motion, when the motor is operating, of a partial minimal rotation to provide the “wobble” to the laser beam 178 projected from the collimator 180 and reflected off of the reflective surface. The laser beam is reflected from the first mirror to a stationary mirror181 mounted to the chassis 147 or otherwise mounted in the interior 182 of the handheld laser tool. Referring to FIG. 9, the stationary mirror 181 may be secured to chassis plate 147.1 which may in turn attach by threaded fasteners to the chassis.

[0049] In embodiments, the two-axis wobble unit 164 further has a second mirrored galvanometer 183 with a rearward second motor 184, a second motor shaft 185 extending from the motor and that connects to a second mirror bracket 188 secured to a second mirror 190. The laser beam reflected off of the stationary mirror 181 projects to the second mirror 190. The second mirror 190 has a reflective surface 192 that faces forwardly. The second mirrored galvanometer is also received by and secured in the bracket 165.

[0050] The specific arrangement of the mirrors and the laser beam path providing the two axis wobble is best shown in FIGS. 5, 11, and 12-14. The collimated laser beam 178 projecting from the collimator 180 is projecting upwardly in an interior of the handgrip to the first mirror 175 of the first mirrored galvanometer 167. The mirror may be oscillating to add an x-axis wobble to the laser beam, the second mirror changing the direction of the laser beam to project more rearwardly and more laterally to strike the stationary mirror 181 positioned in the interior182 of the handheld laser tool on an interior side of the handheld laser tool, and then reflecting the beam from the stationary mirror 181 rearwardly to strike a forward facing mirror surface 192 of the second mirror 190 of the second mirrored galvanometer 183 which may be oscillating to add a y-axis wobble. The second mirror 181 reflects the laser beam forwardly to the focusing lens 140 which converges the laser beam through the nozzle for performing an operation at the discharge opening of the nozzle. In embodiments, the x axis wobble and the y-axis may not precisely overlay the respective actual x and y axis such as set forth in FIGS 6-8. In other words, the wobble provided by each of the respective galvanometers are understood to be about 90 degrees apart. In embodiments the two axess generated by each of the respective galvanometers may be within about 80 degrees to 100 degrees with respect to each other.Attorney Docket No. 5117.0024W01

[0051] In some examples, the handheld laser tool may include a two-axis laser beam wobbling mechanism. This mechanism may be designed to allow for any shape to be projected onto the weld surface, providing a high degree of flexibility and adaptability to different welding tasks. The two-axis wobbling mechanism may be disposed within the compact housing of the handheld laser tool, contributing to the compact and lightweight design of the handheld laser tool.

[0052] In some examples, the two-axis laser beam wobbling mechanism may include a first galvanometer and a second galvanometer. The first galvanometer may be configured to control the wobble in a first axis, while the second galvanometer may be configured to control the wobble in a second axis perpendicular to the first axis. This design may allow for a high degree of control over the wobble pattern, enabling the user to project any shape onto the weld surface.

[0053] In some examples, the first galvanometer and the second galvanometer may be independently controllable. This feature may allow the user to create custom wobble patterns by independently adjusting the wobble in the first and second axes. For example, the user may be able to create a circular wobble pattern by synchronizing the wobble in the first and second axes, or an elliptical wobble pattern by adjusting the wobble in the first axis differently from the wobble in the second axis.

[0054] In some examples, the handheld laser tool may include a controller configured to synchronize the first galvanometer and the second galvanometer. This feature may allow the user to project predefined shapes onto the weld surface by synchronizing the wobble in the first and second axes. The predefined shapes may include, for example, a circle, an ellipse, a figureeight, a square, a rectangle, or a custom user-defined shape.

[0055] In some examples, the two-axis laser beam wobbling mechanism may be designed to be robust and durable, capable of withstanding the harsh conditions often encountered in welding environments. The mechanism may be made from materials that are resistant to heat, corrosion, and mechanical stress, ensuring a long service life and reliable performance. In some examples, the two-axis laser beam wobbling mechanism may be designed to be easy to maintain and service, further enhancing the user-friendliness and operational efficiency of the handheld laser tool.

[0056] When used herein “handheld” means holdable by a user for welding. Handheld laser tools may also be attached to robotic equipment in COBOT applications.

[0057] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scopeAttorney Docket No. 5117.0024W01 of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

Attorney Docket No. 5117.0024W01CLAIMS1. A laser system comprising a handheld laser tool for performing an operation on a workpiece, the handheld laser tool having a body portion and a handgrip portion extending downwardly from a rear portion of the body portion, the handgrip portion of the handheld laser tool having a connection for an optic fiber, or having an fiber optic extending therefrom, for providing a laser beam to the handheld laser tool, the handheld laser tool having a laser beam path therethrough defined by an optics system mounted in the handheld laser tool, the optics system providing a focal point of the laser beam at or forward of a nozzle on a forward end of the body portion for performing the operation, the optics system comprising: a collimator; a reflective mirror for changing direction of the laser beam path; a focusing lens providing the focal point of the laser beam at or proximate the nozzle; a protective window forward of the focusing lens; and a motorized means for moving the focal point with respect to the nozzle, the motorized means including at least one of the reflective mirror or the focusing lens.

2. The laser system of claim 1, wherein the motorized means comprises a dual axis wobble unit comprising a first mirrored galvanometer and a second mirrored galvanometer.

3. The laser system of claim 2, wherein a forward- rearward length of the body portion with the nozzle attached thereto is in the range of 6.0 to 12.0 inches inclusively.

4. The laser system of claim 2, wherein a side-to-side width of the body portion is in the range of 1.0 to 2.5 inches.

5. The laser system of claim 2, wherein a side to side width of the body portion of the handheld laser tool is less than 2.0 inches.

6. The laser system of claim 1, wherein the motorized means for moving the focal point moves the focal point in a z direction during operation of the handheld laser tool as a laser beam is passing therethrough.

7. The laser system of claim 1, wherein the motorized means moves the focal plane of the laser beam in a z direction in line with an axis of the laser beam.Attorney Docket No. 5117.0024W018. The laser system of claim 5, wherein the wobble unit provides an x axis reciprocation and a y axis reciprocation.

9. The laser system of claim 2, the first mirrored galvanometer comprises a rearward motor, a forward reciprocating shaft with a first shaft axis extending from the motor, and a forward fist mirror attached to the forward first reciprocating shaft whereby the forward first mirror reciprocates with the forward first reciprocating shaft, and the second mirrored galvanometer comprises a rearward motor, a forward second reciprocating shaft with a second shaft axis extending from the motor, and a forward second mirror attached to the forward second reciprocating shaft whereby the forward second mirror reciprocates with the forward second reciprocating shaft.

10. The laser system of claim 9, wherein the first mirrored galvanometer is positioned above the second mirrored galvanometer, the first axis and second axis extending forwardly and rearwardly with respect to the handheld laser tool.

11. The laser system of claim 10, wherein the first mirror of the first mirror galvanometer reflects a laser beam from the collimator to a fixed mirror mounted within the body of the handheld laser tool, and wherein the fixed mirror reflects the laser beam to the second mirror of the second mirrored galvanometer, and the second mirror reflects the laser beam to the focus lens in the body of the handheld laser tool.

12. The laser system of claim 8, wherein the first mirrored galvanometer reflects a laser beam extending upwardly from the collimator rearwardly and laterally to a fixed mirror in the handheld laser tool, and the fixed mirror reflects the laser beam rearwardly to the second mirrored galvanometer, and the second mirrored galvanometer reflects the laser beam forwardly to the focus lens.

13. The laser system of claim 12, wherein the first mirrored galvanometer and second mirrored galvanometer are both contained in a galvanometer bracket that positionally fixes first mirrored galvanometer and second mirrored galvanometer with respect to each other, the galvanometer bracket received within the handheld laser tool thereby positioning the respective mirrors of the first mirrored galvanometer and the second mirrored galvanometer into the laser beam path.

14. The laser system of claim 8, wherein the handheld laser tool further comprises a chassis that secures at least part of the optics system within the handheld laser tool, andAttorney Docket No. 5117.0024W01 wherein the chassis has a receiver for the wobble unit positioned at a rearward end of the body portion.

15. The laser system of claim 1, comprising both a single axis wobble unit or a dual axis wobble unit, both of which are received in a receiving region of the handheld laser tool.

16. The laser system of claim 15, wherein the single axis wobble unit comprises a single axis galvanometer with a motor and a reciprocating shaft with a shaft axis, and a mirror on the reciprocating shaft, the mirror having a reflective surface with normal reflective axis extending in a direction perpendicular to the shaft axis.

17. The laser system of claim 15, wherein the dual axis wobble unit comprises a first mirrored galvanometer positioned below the second mirrored galvanometer when installed in the handheld laser tool, both the first mirrored galvanometer and the second mirrored galvanometer have respective axis that extend forwardly and rearwardly with a mirrored end of each of the first and second mirrored galvanometers oriented forwardly.

18. The laser system of claim 17, wherein the first mirrored galvanometer is positioned below and forwardly offset from the second mirrored galvanometer.

19. The laser system of claim 1, wherein the motorized means comprises a wobble unit with a first mirrored galvanometer and a second mirrored galvanometer.

20. The laser system of claim 19, wherein the first mirrored galvanometer and the second mirrored galvanometer in conjunction with a mirror fixed in an interior of the handheld laser tool provide a dual axis wobble of a laser beam extending through the handheld laser tool and with the galvanometers contained within a side to side thickness of the body of the handheld laser tool of 2. 0 inches or less.

21. The laser system of claim 3, wherein the motorized means comprises a wobble unit that provides an x axis reciprocation and a y axis reciprocation.

22. The laser system of claim 1, wherein the motorized means comprises moving the focal point of the laser beam forwardly and / or rearwardly with respect to the nozzle.

23. The laser system of claim 22, wherein the focal lens is mounted to a carriage that moves forwardly and rearwardly by a screw driven by a motor.

24. The laser system of claim 6, wherein the motorized means further comprises moving the focal point of the laser beam forwardly and / or rearwardly with respect to the nozzle.Attorney Docket No. 5117.0024W0125. The laser system of claim 8, wherein the motorized means comprises moving the focal point of the laser beam forwardly and / or rearwardly with respect to the nozzle.

26. A laser system comprising a handheld laser tool for performing an operation on a workpiece, the handheld laser tool having a body portion and a handgrip portion extending downwardly from a rear portion of the body portion, the handgrip portion of the handheld laser tool having a connection for an optic fiber, or having an fiber optic extending therefrom, for providing a laser beam to the handheld tool, the handheld laser tool having a laser beam path therethrough defined by an optics system mounted in the handheld laser tool, the optics system providing a focal point of the laser beam at or forward of a nozzle on a forward end of the body portion for performing the operation, the optics system comprising: a collimator; a focusing lens providing the focal point of the laser beam at or proximate the nozzle; a dual axis wobble unit for providing an x axis and a y axis wobble of the focal point of the laser beam positioned between the collimator and the focusing lens; and a protective window forward of the focusing lens.

27. The laser system of claim 26, wherein a forward- rearward length of the body portion with the nozzle attached thereto is in the range of 6.0 to 12.0 inches inclusively.

28. The laser system of claim 27, wherein a side-to-side width of the body portion is in the range of 1.0 to 3.5 inches.

29. The laser system of claim 26, wherein a side to side width of the handheld laser tool is less than 2.5 inches.

30. The laser system of claim 26, wherein the wobble unit comprises a first mirrored galvanometer and a second mirrored galvanometer, with a mirror of the first galvanometer and a mirror of the second galvanometer both positioned in and defining the laser beam path.

31. The laser system of claim 30 the first mirrored galvanometer comprises a rearward motor, a forward reciprocating shaft with a first shaft axis extending from the motor, and a forward first mirror attached to the forward first reciprocating shaft whereby the forward first mirror reciprocates with the forward first reciprocating shaft, and the second mirrored galvanometer comprises a rearward motor, a forward second reciprocating shaft with a second shaft axis extending from the motor, and a forward second mirror attached to theAttorney Docket No. 5117.0024W01 forward second reciprocating shaft whereby the forward second mirror reciprocates with the forward second reciprocating shaft.

32. The laser system of claim 30, wherein the first mirrored galvanometer is positioned below the second mirrored galvanometer, a first axis of the first mirrored galvanometer and a second axis of the second mirrored galvanometer extending forwardly and rearwardly with respect to the handheld laser tool.

33. The laser system of claim 30, wherein the first mirror of the first mirror galvanometer reflects a laser beam from the collimator to a fixed mirror mounted within the body of the handheld laser tool, and wherein the fixed mirror reflects the laser beam to the second mirror of the second mirrored galvanometer, and the second mirror reflects the laser beam to the focus lens in the body of the handheld laser tool.

34. The laser system of claim 32, wherein the first mirrored galvanometer reflects a laser beam extending upwardly from the collimator rearwardly, upwardly, and laterally to a fixed mirror in the handheld laser tool, and the fixed mirror reflects the laser beam upwardly, rearwardly, and inwardly to the second mirrored galvanometer, and the second mirrored galvanometer reflects the laser beam forwardly to the focus lens.

35. The laser system of claim 30, wherein the first mirrored galvanometer and second mirrored galvanometer are both contained in a galvanometer bracket that positionally fixes first mirrored galvanometer and second mirrored galvanometer with respect to each other, the galvanometer bracket received within the handheld laser tool thereby positioning the respective mirrors of the first mirrored galvanometer and the second mirrored galvanometer into the laser beam path.

36. The laser system of claim 26, wherein the handheld laser tool further comprises a chassis that secures at least part of the optics system within the handheld laser tool, and wherein the chassis has a receiver for the wobble unit positioned at a rearward end of the body portion.

37. The laser system of claim 26, wherein the dual axis wobble unit comprises a first mirrored galvanometer positioned below the second mirrored galvanometer when installed in the handheld laser tool, both the first mirrored galvanometer and the second mirrored galvanometer have respective axis that extend forwardly and rearwardly with a mirrored end of the first and second mirrored galvanometers oriented forwardly in the handheld laser tool.Attorney Docket No. 5117.0024W0138. The laser system of claim 37, wherein the first mirrored galvanometer is forwardly offset from the second mirrored galvanometer and the respective axes are parallel.

39. The laser system of claim 30, wherein the first mirrored galvanometer and the second mirrored galvanometer in conjunction with a mirror fixed in an interior of the handheld laser tool provide a dual axis wobble of a laser beam extending through the handheld laser tool and with the galvanometers contained within a side to side thickness of the body of the handheld laser tool of 2.0 inches or less.

40. The laser system of claim 26, wherein the focal lens is mounted to a carriage that moves forwardly and rearwardly by a screw driven by a motor.

41. A laser system comprising a handheld laser tool an elongate handgrip portion with an handgrip axis and a body portion with a body portion axis joined to the handgrip portion, the handheld laser tool having a connection portion for receiving a laser fiber, the handheld laser tool comprising: an optics system including a dual axis wobble unit providing an x axis wobble and a y axis wobble, and wherein a width of the handheld laser tool with the dual axis wobble unit therein is less than 3.0 inches.

42. The laser system of any of claims 1-41, wherein the handheld laser tool has a mirrored galvanometer comprising: a motor with a shaft extending therefrom along a shaft axis, the motor providing a oscillating partial rotation of the shaft within a limited angular rotation range; a mirror bracket affixed to the shaft such that the mirrored bracket rotates with the motor shaft, the bracket having a support member extending radially outward from the mirrored galvanometer axis and axially forward; a mirror affixed to the mirror bracket at a bracket-mirror juncture; the mirror having a laser beam reflective side with a laser beam reflective surface and an opposite side, the mirror positioned with the reflective side facing rearwardly, wherein an open laser beam path is provided that transverses through the axis between the mirror and the motor.

43. The laser system of claim 42, wherein the bracket is configured such that the open laser beam path is not obstructed by the mirror bracket.Attorney Docket No. 5117.0024W0144. The laser system of claim 42, wherein the mirror bracket is U-shaped with a lower leg of the U-shape connecting to the motor shaft and two upper legs of the U-shape each respectively connecting to the mirror.

45. The mirrored galvanometer of claim 42, wherein mirror is positioned such that a mirror reflective axis forms an angle open rearwardly with the mirrored galvanometer axis in the range of 10 degrees to 60 degrees.

46. The laser systems of any one of claims 1-41, wherein the optics system includes a first mirrored galvanometer having a rearward motor, a forward mirror attached to a reciprocating shaft extending forwardly from the motor, a mirror connected to the shaft, the mirror having a laser beam receiving side facing rearwardly, the mirror having a laser beam reflective surface positioned such that an axis of the reciprocating shaft extends through the reflective surface.

47. The laser system of claim 46, wherein the reflective surface faces mostly rearwardly.

48. The laser system of claim 46, wherein a plane of the reflective surface and the axis of the reciprocating shaft defines a rearward angle of between 5 degrees and 80 degrees.

49. The laser system of claim 46, wherein the mirror connects to the reciprocating shaft by way of a bracket that has a mirror connection that is offset from the axis of the reciprocating shaft.

50. The laser system of claim 46, wherein a normal axis of the reflecting surface of the mirror extends forwardly and rearwardly.

51. The laser system of claim 46, wherein a normal axis of the reflecting surface of the mirror extends primarily in an axial direction rather than a radial direction with respect to the axis of the reciprocating shaft.

52. A handheld laser tool comprising: a compact housing; and a two-axis laser beam wobbling mechanism disposed within the housing, the wobbling mechanism configured to project any a two dimensional shape onto a weld surface, the compact housing being less than 2.0 inches in width.

53. The handheld laser tool of claim 52, wherein the two-axis laser beam wobbling mechanism comprises:Attorney Docket No. 5117.0024W01 a first galvanometer configured to control wobble in a first axis; and a second galvanometer configured to control wobble in a second axis perpendicular to the first axis.

54. The handheld laser tool of claim 52, wherein the first galvanometer and the second galvanometer are independently controllable to create custom wobble patterns.

55. The handheld laser tool of claim 52, further comprising a controller configured to synchronize the first galvanometer and the second galvanometer to project predefined shapes onto the weld surface.

56. The handheld laser tool of claim 55, wherein the predefined shapes include at least one of: a circle, an ellipse, a figure-eight, a square, a rectangle, and a custom user-defined shape.

57. The laser systems of any one of claims 1-41, wherein the optics system of the handheld laser tool has two mirrored galvanometers providing a dual axis wobble and the maximum width of the body portion housing of the handheld laser system is less that 2.5 inches.

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