Laser Based Fabrication of Freeform Optics

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PowerPhotonic has pioneered an innovative laser micro-machining process to produce precision, free-form micro-optics. Our manufacturing technology, based on fundamental research carried out at Heriot-Watt University, enables us to rapidly iterate prototypes without setup costs at short turnaround times, and to cost-efficiently produce high-volume custom optics. The successful applicant will investigate new and improved methods of fabricating freeform micro-optics fabrication that will encompass: originating and investigating, new and improved methods of forming optical surfaces in a range of materials; coupling these forming methods to new and improved approaches in surface-finishing; and exploring new approaches to process metrology. The aim is to provide PowerPhotonic with the next generation of process technology based on fundamental research, and we expect this project to substantially further the company's capabilities - how to go deeper, steeper, with a faster process, improving device performance and quality. The project will cover technologies from Selective Laser Etching and Femto-second Laser Processing, to Laser Smoothing, and potentially Ultra Precision Machining. The investigator in this applied EngD will be a member of PowerPhotonic's R&D Technology Acquisition team, working onsite in Dalgety Bay (Fife), as well as at Heriot Watt University (Edinburgh) and potentially (and for very short periods) at third party locations (supported throughout by PowerPhotonic). During the project, the applicant will build a diverse skillset in the modelling, design, and the realisation of process technology. As such, they should have an enthusiasm for tackling challenging problems across a range of topics such as system design, laser-based materials processing, and optical surface metrology, as well as technologies associated with these topics.The research direction we propose in the project abstract (reiterated above, [b]) will generate a novel forming-and-finishing process. We aim to be unique in the industry. Some of the forming technologies exist at very low TRL. They are solutions looking for problems, much like the invention of the laser itself. The finishing technology is little understood, and often crudely deployed, outside of PowerPhotonic. We have taken this embodiment of the process as far as we wish to, and require a next generation leap. Outside of this project (PowerPhotonic and Heriot-Watt) we're aware of nobody working in this area, and certainly nobody with the head start we possess.