Laser Nanofactory

SPECIFICATIONS
Laser Nanofactory
  • Workstation for femtosecond laser multiphoton polymerization, selective laser etching and laser ablation processes
  • High quality femtosecond laser with user required parameters
  • Stitching error-free manufacturing over the entire working area (160 x 160 x 60 mm)
  • Universal vacuum sample holder with computer-controlled and position-synchronized illumination
  • Optical modulator and motorized attenuator for beam power control
  • Powermeter for real-time power monitoring
  • High sensibility camera for real-time process management
  • Workstation is protected against environmental vibrations
  • The system is compact and convenient, dimensions – 1.86 m, footprint – 1.14 m x 0.92 m.
  • Laser Nanofactory weights about 700 kg.
  • The laser safety of the system is Class 1 during the operation, when the main door is closed
  • Laser Nanofactory has CE certification
System description
Femtika designs customized systems for laser micro-fabrication process. Laser Nanofactory workstation combines additive and subtractive manufacturing – for this reason complex micro-devices of several different materials can be fabricated. System is equipped with femtosecond laser of high beam quality (M2~1.2-1.3) and user-required wavelength (usually 1030 nm, 515 nm, 780 nm or can be dual-wavelength). Also, the average power of the integrated laser is selected based on desired customer application (from 250 mW to 20 W). The ultra-precise positioning stages (resolution 1 nm @XY, 2 nm @Z; repeatability 75 nm @XY, 100 nm @Z; accuracy ±300 nm @XY, ±275 nm @Z) are synchronized with galvano-scanners,  resulting in stitching-error-free manufacturing over the entire working field (160x160x60 mm) without sacrificing the speed or the quality. Whole parts of the system are integrated in one ergonomic housing, ensuring better safety and environmental stability conditions.
3DPoli software
3DPoli is a flexible and easily controllable software, dedicated for science and research. The main purpose of 3DPoli is to control the equipment used for three-dimensional direct writing setups, such as two photon polymerization, 3D glass inscription and others.

The software is divided into the two applications: 3DPoli Compiler and 3DPoli Fabrication. The Compiler is used for defining the structures (motion profiles). It does not require the system connected and can be easily copied to other computers (e.g. home computer) for convenience. The Fabrication part works only on a licensed computer with all the devices connected. It receives the compiled data from the compiler and performs the structure fabrication.

  • The software allows direct power tunability through the laser and position-based pulse picker control.
  • Precise control of several devices (Rotary, linear, piezo stages, galvanoscanner, power attenuator, laser shutter, etc.).
  • The whole writing process is automated.
  • Internal programming language.
  • Automatic calculation of various structure parameters and estimated fabrication time.
  • 3D fabrication trajectory preview window.
  • An easy-to-use graphical user interface. 
  • The software has access to all necessary hardware parameters for controlling fabrication process.
  • 3DPoli software handles standard formats of 3D designs created by popular CAD programs, like STL. 
  • Sample coordinate system alignment (tilting and rotation).
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SPECIFICATIONS

Femtosecond Laser

System is equipped with femtosecond laser of high beam quality (M2~1.2-1.3) and user-required wavelength (usually 1030 nm, 515 nm, 780 nm or can be dual-wavelength). Also, the average power of the integrated laser is selected based on desired customer application (from 250 mW to 40 W).

Nanopositioning

The ultra-precise positioning stages (resolution 1 nm @XY, 2 nm @Z; repeatability 75 nm @XY, 100 nm @Z; accuracy ±300 nm @XY, ±275 nm @Z) are synchronized with galvano-scanners,  resulting in stitching-error-free manufacturing over the entire working field (160x160x60 mm) without sacrificing the speed or the quality.

Stitching-free manufacturing
The microfabrication process can be implemented by moving the laser beam in the volume of the material (using galvanoscanners) or by moving the sample (translation stages). Both ways have its disadvantages and fast stiching-free fabrication of complex true 3D centimeter-sized quality structures cannot be achieved. 

This problem can be solved with synchronization of galvanoscanners and translation stages. This way the translation stages makes long and continous movements and galvanoscanners makes fast movements. As a result continous movement of working field is achieved, avoiding stitching and keeping very high fabrication speed and quality.

Sample holder

Laser Nanofactory is equipped with universal vacuum sample holder with computer-controlled, position synchronized illumination for transparent samples. Illuminated area - 14 x 66 mm (for microscope slide). Samples of different geometries (circular, rectangular and square) can be attached to the holder with vacuum. It has ability to easily change plates (porous ceramics) of sample holder for chucking the wafers. The design of sample holder can be customized due to specific needs of the client. 

Additive manufacturing

Additive manufacturing is based on 3D printing principle, multi-photon polymerization process. Microfabrication by multi-photon polymerization is a direct laser-write technique which allows 3D sturcturing of photopolymers at the micro- and nano-scale. This can be achieved through combination of various nonlinear effects, careful consideration of laser radiation parameters and precise focusing conditions. For this reason 3D laser lithography was used for creation of functional devices in fields of nanophotonics, microoptics, microfluidics, micromechanics, tissue engineering and much more. It is important to note, that there is huge variety of materials that can be processed by applying 3D laser lithography, including hybrid organic-inorganic photopolymers, biodegradable polymers, elastomers, proteins and so on.

Subtractive manufacturing

Subtractive manufacturing is based on laser ablation and selective laser etching techniques. 

Laser ablation based on ultra-fast interaction between material and femtosecond laser irradiation allows "cold processing" with minimal thermal effects and superb cut quality without damaging the surrounding material. Almost any material can be processed: metals, polymers, glass, even paper (banknotes, for example).

Selective laser etching is a two-step process. First, the volume of glass or sapphire is modified by ultra-short pulsed radiation, then the material is chemically etched away. In this way mechanically stable and durable structures can be created.

Surface structuring

Laser Nanofactory system can be used for the treatment of surface areas - nano- to mili-patterning for enhanced surface repelling, adhesion properties.

Example applications: 

  anti-bacterial, self-cleaning surfaces for medical implants;
  surface friction reduction between parts of ship and water;
  propellers and blades with anti-icing properties, reduction of friction between parts of airplane and air;
  heavy machinery with heat dissipation, self-cleaning properties.
Video
Femtosecond laser hybrid micro-fabrication video.
Files
Catalog: workstation and example structures.