Laser Optical Engineering Ltd

Innovative and Bespoke Laser Systems

dlloyd@laseroptical.co.uk

+44(0)1322 814612

Laser Surface Modification

3D Moulded Circuits

1. What were we doing?

2. Laser materials processing

3. Laser surface modifications

4. Specific project challenges

5. Applications and the future

6. Question time

www.natep.org.uk 2

Materials finishers: Moulded Circuits

Limited • Moulded Circuits Ltd have been established for over 25

years and specialise in the design and supply of

advanced plated plastics and 3D electrical circuitry to the

Industrial, Telecommunications, Medical, Automotive and

Aerospace industries.

• Laser Optical Engineering Ltd (LOE) specialises in the

development of innovative and bespoke laser based

products and services and was established as an

independent spin-out company from Loughborough

University in 1996

• Funded by NATEP

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Object of the Project

○ End user: OEM – want highly functional and very precise circuitry. Want to provide new components to reduce weight or increase functionality

○ Moulded Circuits Limited: MCL provide the materials technology for the successful generation of 3D metal connections on polymer parts

○ Laser Optical Engineering Ltd: LOE offer a range of laser system development and consultancy services

Not to be reproduced without permission

What is a laser?

Wavelength

Thin layers

Laser selection

Pulsed Vs CW

Threshold

CW

Time

Ener

gy

Pulsed

Lasers cutting

Real laser cutting

Dr Jonathan Blackburn TWI Ltd, Cambridge, 2012

http://www.industrial-lasers.com/articles/print/volume-27/issue-03/features/a-new-method-of-laser-surface-modification.html

Moving

Cleaning

Addition (and welding)

Laser marking

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○ Most systems have ‘2.5D’, some vertical movement but limited ability to stitch areas across a complex surface

Videos: EOX lasers; Keyence

What is marking? ○ Black mark

○ Deep burn

○ White mark

○ Surface ‘scratching’

○ Annealing

○ Multiple layers giving colour

○ Ablation

○ Removal of material

Ablation: Excimer machining

https://www.researchgate.net/profile/Salem_Saadon/publication/2832

78426/figure/fig-4Images-of-excimer-laser-cuts-on-four-materials-

6.png

Metal gratings

Laser measuring

• Point or line

• Build up a series of

measurements

• Transform into a

surface

– Roughness

– Profile/shape

Laser shearography

• Testing for internal

defects in composite

and coated structures

– delamination

– Disbonds

– Damage

– Blistering

Object of the Project

○ MCL are pushing the limits of their current technology to achieve OEMs requirements

○ Some foreign technology (LPKF) is able to partially meet foreseen challenges

○ Approached LOE to see if we could work with them to do something better

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Current process Primer printed

Body polymer

Metallic added

Metallic thickness grown

Project innovation: micro ablation Primer

Body polymer

Metallic added

Metallic and primer removed

Primer removed

Metallic added

Material calibration

System demonstration

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What can we offer?

○ Rapid manufacturing of 3D metallic tracks.

○ Tailoring process for track formation on a range of polymeric surfaces.

○ Supply of complete part from customers design or patterning of customer manufactured part

○ We can create brand new markets e.g. by functionalising carbon fibre structural components.

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What have we achieved? ○ New system capable producing complex finishes on parts

○ A method of producing electronic functionality onto the surface of 3D structural components.

○ Ability to reduce part count and simplify structures by combining electronic and structural parts

○ More energy efficient manufacturing of multi-functional components

○ Electronics manufacturers will realise designs that were previously uneconomical or impossible to produce

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Where now?

○ Current system is a development prototype

○ LOE intend to use this to work with MCL to optimise processes

○ MCL well placed to exploit outcomes

○ Known in market

○ Customer contacts and relationships

○ Have design expertise and coating capability across a wide range of materials and

○ Thanks to NATEP funding scheme MAA045

www.natep.org.uk

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www.natep.org.uk

Project Partners :- Moulded Circuits Limited Laser Optical Engineering MBDA

3D Moulded Circuits MAA 045

Contact details

29 www.natep.org.uk

Pete Stone MOULDED CIRCUITS Ltd 1142 Melton Road Syston Leicestershire LE7 2HA Tel: 0116 260 9841 Fax: 01162698392 Pete@mouldedcircuits.co.uk

Daniel Lloyd LOE Unit 72A Argosy Road East Midlands Aiport De74 2SA 01332 814612 dlloyd@laseroptical.co.uk