kW-Flexiburst aimed to enable the next generation of laser systems for material processing by developing a disruptive laser technology to deliver higher precision, throughput and, most importantly, extreme flexibility.

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The Need for Next-Generation Lasers

Current ultrafast laser technology has demonstrated applicability for enabling high precision micromachining. However current throughput is not efficient enough for widescale industrial manufacturing. The parameters of existing lasers are not flexible enough to consistently work in the optimal conditions necessary to reach the highest precision while using all available laser power. The kW-flexiburst project aimed to develop a disruptive laser technology to help overcome this critical barrier, which could enable the next generation of manufacturing in a range of industrial sectors. 

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Remarkable Achievements

The consortium achieved an impressive 1 kW of average power with pulse durations of just 1.5 picoseconds (ps). This level of control and power represents a game-changing development for industrial applications.

The kW-Flexiburst project has delivered groundbreaking results, showcasing its potential to revolutionize industrial manufacturing:

• kW-class ultrafast laser source: Successfully demonstrated several different configurations including GHz bursts with few and high number of pulses in the burst

• Extremely high aspect ratio drilling with GHz bursts and high-speed stealth dicing (0.5 m/s)

• Fast engraving of cylindrical rollers: Achieved at 1 m² per 46 minutes.

• Exceptional ablation rates: Reached 100 mm³ per minute and drilled up to 4000 holes per minute on ceramic substrates.

• Laser turning: Demonstrated precision shaping of holes and micro-components.

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Real-World Impact

The success of kW-Flexiburst has already spurred tangible advancements:

• Two new commercial products, IceFyre FS UV50 and IceFyre FS IR200, launched as direct outcomes of the project.

• Two ambitious internal projects initiated by industrial partners to explore the technology’s promising potential further.

• A new startup, Synthwave Lasers, established to capitalize on the breakthroughs.

​Beyond commercial applications, the research has led to significant scientific contributions, including multiple high-impact journal publications and one patent.

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Transforming the Future of Manufacturing

As the project transitions to its next phase, the innovations of kW-Flexiburst stand as a testament to the power of collaboration, research, and forward-thinking engineering. Stay tuned as these advancements continue to shape the future of industrial manufacturing.