Additive manufacturing AM), esp. laser AM, becomes a powerful tool to replace conventional methods due to its cost effectiveness and capability of making complex structure and composition. However, direct fabrication of optics parts is still a challenging field, mainly due to limited understanding of process control, powder fabrication, and laser melting mechanism to eliminate defects and bubbles. Statement of how this problem or situation is being addressed. Based on our patented laser AM technology and the worlds first demonstration of fs fiber laser AM system 2016 R&D Award), PolarOnyx proposes, for the first time, a pulsed UV fiber laser based AM process to overcome these difficulties and meet the requirement of making capillary optics just in one process. The UV beam is shaped to have same size and shape of the capillary optics at a given layer position so the whole layer of nano-particle is melt simultaneously to eliminate the thermal induced stress in the final product. The SM function gives trimming and defect correction for the processed glass parts. This multi- functional capability SM and AM) is not achievable for CW laser AM and will significantly reduce the building time and cost. Commercial Applications and Other Benefits. In addition to the 3D AM applications, material processing is another major commercial application for this project. This includes 1) Photonic device fabrications, such as waveguide, coupler, WDM, modulator, and switching; 2) all types of metal processing such as welding, cutting, annealing, and drilling; 3) semiconductor and microelectronics manufacturing such as lithography, inspection, control, defect analysis and repair, and via drilling; 4) marking of all materials including plastic, metals, and silicon; 5) other materials processing such as rapid prototyping, desk top manufacturing, micromachining, photofinishing, embossed holograms, and grating manufacturing.
