Laser Orifice Drilling Thickness Compensation
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Solution Overview
Problem
Conventional methods struggle to precisely control the drilling of orifices in thin, flexible materials with non-uniform wall thickness, such as balloon catheters, due to the inability to accurately manage laser drilling parameters in response to varying thicknesses, resulting in inconsistent exit diameters and flow rates.
Innovation Solution
The method involves creating a thickness profile of the wall and adjusting laser parameters like pulse number, duration, energy, and beam size in real-time during the drilling process, using techniques like monitoring acoustic signatures and automated vision to ensure precise control of orifice dimensions, particularly by pre-mapping thickness, local monitoring, preliminary drilling of sub-sized orifices, and constant exit diameter monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser drilling is used on thin-walled devices with non-uniform thickness, then the drilling process is simple and fast, but the exit diameter consistency and manufacturing precision deteriorate
Solution Approach 1:
The system performs preliminary mapping of the wall thickness profile before drilling, storing this information for use during the drilling process. This preliminary action enables the control system to pre-calculate appropriate laser parameters for each drilling location based on the anticipated wall thickness, thereby maintaining both high productivity and precise exit diameter control.
Solution Approach 2:
The laser drilling parameters (pulse energy, pulse duration, pulse frequency, spot size) are dynamically adjusted in real-time based on the measured or mapped wall thickness at each drilling location. This dynamic adaptation allows the system to maintain consistent exit diameters across non-uniform walls without sacrificing drilling speed, as parameters are automatically modified for each position.
2Manufacturing precision
If laser parameters are adjusted in real-time based on thickness profile, then the exit diameter precision is improved, but the device complexity and process time increase
Solution Approach 1:
The system incorporates feedback mechanisms where the measured or mapped wall thickness information is fed back to the control system, which then automatically adjusts laser parameters accordingly. This closed-loop feedback enables precise exit diameter control without requiring complex manual intervention, as the system self-regulates based on real-time or pre-acquired thickness data.
Solution Approach 2:
The system creates a digital copy or map of the wall thickness profile that can be stored and referenced during drilling. This virtual model allows the control system to retrieve pre-calculated parameter settings based on the thickness map, reducing the need for complex real-time calculations and simplifying the control architecture while maintaining precision.
3Manufacturing precision
If preliminary thickness mapping is performed, then the manufacturing precision is improved, but the process time and productivity are reduced
Solution Approach 1:
The thickness mapping is performed as a preliminary action using rapid non-contact methods such as optical scanning or acoustic signaling during a single pass. This preliminary measurement captures the wall thickness profile quickly without requiring multiple measurements or slowing down the subsequent drilling process, as the data is acquired in advance and used to guide parameter selection.
Solution Approach 2:
The thickness mapping and drilling operations are integrated into a continuous process where the mapping is performed while the device is positioned for drilling, and the parameter adjustments are made seamlessly during the drilling sequence. This continuous operation minimizes idle time and ensures that the preliminary mapping does not create significant delays in the overall manufacturing process.
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 approach enables the precise machining of orifices with controlled exit diameters in thin-walled devices with non-uniform thickness, enhancing the accuracy and consistency of fluid administration in medical applications by compensating for thickness variations during the laser ablation process.
Implementation Method 1
Laser ablation is the process of removing material by irradiating it with a laser beam. At lower laser energy densities, the material is heated by the absorbed laser energy and melts, evaporates and/or sublimates. At high energy densities, the material is typically converted to gas or plasma and expands away from the surface.
Implementation Method 2
Ablation requires sufficient absorption of the laser light by the material. Absorption wavelength characteristics are material-specific.
Implementation Method 3
monitoring acoustic signatures
Data Source
AI summary
Methods and systems for drilling precise orifices in a wall of non-uniform thickness are provided. In one aspect, a thickness profile of at least a portion of the wall is created and the wall is irradiated with at least one laser beam to ablate a portion of the wall to thereby form an orifice in the wall. During the irradiation, one or more parameters of the least one laser beam are adjusted one or more times in accordance with the thickness profile to compensate for the non-uniform thickness of the wall.