Making “Light” Work of Automated Surface Processing with USPL Lasers

Femtosecond laser surface processing has transitioned from the laboratory to robotic implementation for large-scale components, thanks to advancements by the US Air Force and the Robo-CLASP project, led by the University of Dayton Research Institute. High powered commercial-of-the-shelf femtosecond laser power sources (300W), novel hollow-core fiber (HCF) manufacturing and HCF coupling, and in-situ process monitoring techniques, when combined, allow for robotic integration enabling process of components at a scale (10s of meters) at a rate competitive with traditional methods for applications such as grit blasting, manual sanding, and chemical stripping.

This presentation will discuss the mechanical bond strength of prepared surfaces for bonded coupons, thermal properties, and laser quality achieved using this robotic system. The critical role of in-situ process monitoring and feed-forward control in maintaining focus and ensuring process stability on complex geometries will be highlighted. Furthermore, data on process rate and cost will be presented, demonstrating the technology's current viability and outlining its potential to shape future research and commercial laser development in areas such as coating removal/machining, surface functionalization, and other surface preparation applications.