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Beam shaping is a critical technique for optimizing laser performance in industrial manufacturing but the high thermal loads of the laser limits the development of optical beam shaping systems to few systems able to produce a single basic shape.

We present a groundbreaking adaptive beam shaping system based on a deformable mirror that produces multiple shapes by dynamically correcting the wavefront distortions in real time. The closed-loop control is assured by a low power laser separated from the high power laser path whereas an active cooling stabilizes the temperature of the mirror when irradiated by laser up to 4 kW.

Our technology represents a versatile solution matching multiple needs of laser manufacturing processes and boosting their productivity and quality.

The presentation will highlight the system design and the results of preliminary tests.

Laser welding is widely used in electric vehicle manufacturing but faces challenges like weld defects and instability at high speeds. Laser beam shaping has emerged as a promising solution. This study investigates the impact of both static and dynamic beam shaping techniques on weld quality in e-mobility applications. Using detailed computational fluid dynamics (CFD) simulations, we analyze how different beam intensity profiles influence melt pool behavior, fusion zone geometry, and keyhole-induced porosity. The model includes complex physical effects such as multiple reflections, phase transitions, surface tension, buoyancy, and Marangoni flows. Results show that beam shape significantly affects maximum and average temperatures and velocities inside the melt pool which relate to process stability, spatter, and pore formation. These insights support the development of optimized beam profiles for improved welding performance in automotive applications.

The ongoing electrification of drives is increasing the importance of processing copper materials, particularly in welding. A highly automatable and flexible joining method for copper materials is laser welding. Literature indicates that the process can be stabilized using laser radiation in the visible wavelength range or through beam oscillation.

This paper describes the concept and design of a new beam source with a 532 nm laser beam wavelength at the highest beam quality and with up to 500 W laser output power. This was achieved using a coherent beam combination in the green wavelength range, the CBC-green-laser.

The use of this novel high-brilliance continuous-wave laser source in the visible range was inves-tigated in comparison to established remote laser methods using near-infrared radiation and ex-amines the benefits of 532 nm wavelength for highly reflective copper materials. This provides users and developers with validated insights for future developments in the e-mobility market.

Owing to the complex clamping requirements, accurate positioning and limited available area for processing, welding can be classified as a critical process in manufacturing of metallic bipolar plates. A shielding gas assisted welding process is used for isolating oxygen from the process zone and to help reduce weld spatter. The gas flow rate can influence the dynamics of melt pool and material solidification which may aid to improve the seam quality. A system was developed for local provision of the gas during the laser welding of bipolar plates. The system can be attached to the clamping fixture to ensure even distribution of the gas in targeted locations and allows the adjustment of the gas flow rate as per requirement. Various shielding gas supply configurations were tested to verify the most effective design for optimal distribution of the gas and cross-sections of weld seams were compared.