Compact Flat Top Beam Shaping Optics for High Power Lasers

Описание: Compact Flat Top Beam Shaping Optics for High Power Lasers
Contact us for technical guidance or a quote: [email protected]
http://www.dmphotonics.com

The Extra Small (XS) Top Hat Shaper is a compact beam-shaping optical solution designed to transform a Gaussian laser beam into a uniform flat-top (Top Hat) intensity profile while occupying minimal physical space. It addresses a growing need in modern laser systems where optical performance must be maintained despite tight mechanical constraints, compact laser heads, and integrated OEM architectures.

Unlike standard focusing or beam expansion optics, a Top Hat Shaper redistributes optical energy to achieve a nearly constant irradiance across the beam cross-section, with steep intensity roll-off at the edges. This uniformity is critical in applications where consistent laser–matter interaction is required across the entire illuminated area. The XS format achieves this performance in an ultra-compact footprint, enabling integration into scanners, galvo heads, sealed laser modules, and portable or embedded systems.

The optical design is typically refractive, allowing high transmission efficiency and excellent power handling compared to diffractive solutions. Refractive Top Hat shaping avoids the wavelength-dependent efficiency losses and unwanted higher diffraction orders that can limit performance in high-power or broadband laser applications. As a result, XS Top Hat Shapers are well suited for continuous-wave, nanosecond, picosecond, and femtosecond laser sources across UV, visible, and infrared wavelengths.

Uniform intensity delivery offers clear process advantages. In laser micromachining, it reduces edge overheating, minimizes taper, and improves feature repeatability. In surface treatment and annealing, a flat-top beam ensures homogeneous energy deposition, leading to consistent material modification and improved yield. For lithography, imaging, and mask illumination, the sharp beam edges and high flatness support precise pattern definition and reduced exposure variability.

Despite its small size, the XS Top Hat Shaper is engineered for high damage thresholds and thermal stability, making it compatible with high average power and high repetition rate laser systems. The compact form factor does not compromise beam quality, preserving wavefront integrity and enabling downstream focusing or scanning without introducing significant aberrations.

Another key advantage is simplified system integration. The reduced optical length allows designers to eliminate folded beam paths or oversized housings, contributing to smaller, lighter, and more robust laser platforms. This is particularly valuable in OEM environments where space, weight, and reliability are tightly constrained.

Overall, the Extra Small Top Hat Shaper represents a convergence of beam uniformity, compactness, and industrial robustness. By delivering flat-top performance in a miniature optical package, it enables precision laser processing and illumination in systems where conventional beam shapers cannot be accommodated.

Del Mar Photonics, Inc. is a leading manufacturer and system integrator of advanced photonics products for scientific and industrial applications. We offer a comprehensive range of lasers, optics, optical crystals, and related instrumentation to support cutting-edge research and development. Our unique capability lies in delivering fully customized optical components and assemblies that combine nanometer-level precision fabrication across the UV to far-IR spectrum with advanced durable coatings, ensuring high-performance, environmental resilience, and laser-ready operation.
We welcome opportunities to collaborate with researchers and instrumentation developers on custom OEM systems tailored to specific application needs. Contact us for technical guidance or a quote: [email protected]
http://www.dmphotonics.com

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