Fiber Launcher Corrective Optic for Beam Precision
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Solution Overview
Problem
Current fiber laser systems face challenges in achieving high precision and scalability due to the limitations of high-precision fiber arrays, which are complex and costly, especially for applications requiring megawatt-class power and adaptive phased arrays.
Innovation Solution
A fiber launcher assembly utilizing a low precision fiber array coupled with a corrective optic, where metrology is performed to determine a composite profile, and a corrective map is calculated and fabricated to align the microlenses in the optic, allowing for the output of light beams to propagate in a substantially parallel direction, mimicking a high-precision array at a fraction of the complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high-precision fiber array is used to achieve diffraction-limited beam combining, then beam quality and precision are improved, but device complexity and cost increase significantly
Solution Approach 1:
A corrective optic acts as an intermediary element between the low-precision fiber array and the beam combining system. This optic contains microlenses with precisely controlled surface heights that compensate for the positional errors of individual fibers, effectively mediating between the imperfect input array and the required high-precision beam output
Solution Approach 2:
The corrective optic creates a virtual copy of the ideal high-precision fiber array by using metrology measurements to determine a composite profile, calculating a corrective map, and fabricating microlenses that replicate the optical function of a precision array while using inexpensive low-precision physical fibers
2Manufacturing precision
If a high-precision fiber array is used to achieve diffraction-limited beam combining, then beam quality is improved, but cost increases significantly
Solution Approach 1:
The system replaces expensive, difficult-to-manufacture high-precision fiber arrays with inexpensive low-precision fiber arrays combined with a single corrective optic. The corrective optic, while precision-fabricated, is a one-time component that enables the use of大量 cheap fibers, dramatically reducing overall system cost
Solution Approach 2:
Metrology measurements are performed in advance to determine the composite profile of the low-precision fiber array. This preliminary characterization data is used to calculate the corrective map that guides the fabrication of the corrective optic, ensuring high-precision output before the actual beam combining operation
3Power
If fiber count is increased to achieve higher power output, then power scaling is improved, but alignment precision requirements become more stringent
Solution Approach 1:
The corrective optic performs self-correction by containing microlenses whose surface heights are specifically designed to compensate for the cumulative positional errors of large numbers of fibers. Each microlens independently corrects the trajectory of light from its corresponding fiber, allowing the system to maintain precision even as fiber count increases to thousands of elements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the achievement of high-precision, diffraction-limited laser beam combining with reduced complexity and cost, allowing for scalable fiber counts from 2 to 10,000, suitable for megawatt-class laser systems and material processing applications.
Implementation Method 1
a corrective optic aligned with and spaced apart from the low precision fiber array. The plurality of optical signals output from the low precision array to the corrective optic have a given trajectory and optical signals output from the corrective optic have a substantially parallel trajectory different from the given trajectory
Data Source
AI summary
An optical fiber launcher assembly can include a low precision fiber array that outputs a plurality of optical signals from a given side that are input into an opposing side. The optical fiber launcher assembly can also include a corrective optic aligned with and spaced apart from the low precision fiber array. The plurality of optical signals output from the low precision array to the corrective optic have a given trajectory and optical signals output from the corrective optic have a substantially parallel trajectory different from the given trajectory.