When industrial surface preparation requires high throughput, consistent results, and maximum safety, automated laser cleaning workcells provide an effective solution. In this blog, we highlight the CleanTech Industrial Robotic Cell 6040 (or CTIR-6040 for short) – uniquely combining a collaborative robot (cobot) and laser cleaning technology within a CDRH Class I laser-safe workcell.
The Lasing Process
All products in the CleanTech product line by Laser Photonics rely on laser ablation to remove unwanted layers from various materials. Generated inside an ytterbium-doped optical fiber and directed by a scanner with galvo motors out and onto the surface, a laser beam heats up a contaminant and vaporizes it at its ablation threshold. The process involves no consumables or mechanical impact. It is a non-contact procedure, ideal for high-precision and environmentally conscious applications.
While laser processing is highly versatile, various materials require different lasing parameters. The operator can modify the following: a laser’s pulse duration, frequency, and power. In addition, the area of the ablation pattern and the pattern itself are adjustable; the operator can select from several preset patterns or create a custom pattern that will best suit the process.
The CTIR-6040 combines this laser ablation technology with collaborative robotics to streamline time-consuming, repetitive surface preparation tasks.
Operating the Cobot
Inside the walk-in workcell of the CTIR-6040, a robotic arm with an integrated laser scanhead reaches about 50 inches in any direction across the heavy-duty processing table. Components are secured onto the table with fixtures in a way that allows for streamlined part re-installation in multiple rounds of treatment – this is an important step that saves time and labor.
Next, the operator can set up the processing in two ways: either by entering the part coordinates on the touchscreen automation pendant, or by manually moving the robot arm in the “collaboration” mode. The cobot will replicate the movement precisely, including head tilts for 3D cleaning applications, activating the laser over the set coordinates. This latter, intuitive programming technique allows the operator to bypass the step-by-step entry of parameters for processing. The collaborative method is accessible to users with minimal technical expertise, allowing for easy integration into various workflows.
Semi-automated laser cleaning is particularly convenient for repetitive tasks. The cobot can precisely, consistently replicate the taught sequence of movements, minimizing error and increasing throughput. This reduces the time spent on programming and allows for quick modification.
The Custom Workcell
The CTIR-6040 comes with custom configurations to meet the unique needs of each client. Customization involves the design of the workcell itself to fit properly into your space, accommodate part specifications, and integrate with existing workflows, as well as to ensure adherence to safety requirements. Initially assembled in a CDRH Class IV three-wall setup with an entryway and a laser-safe front window, our engineers readily turn the CTIR-6040 into a fully enclosed Class I workcell with effective fume filtration.
Use Case: Optical Coating Removal
Here’s a use case where the CTIR-6040 removed anti-reflective optical coating from specialized lens holder trays.
The trays, provided by a prominent optical company, were shaped like triangular segments of a sphere with placeholders for eyeglass lenses. They had accumulated a build-up of coating material from repeated use in vacuum coating processes, which rendered them unusable for their intended purpose.
To address this, the CTIR-6040 was programmed using collaborative mode to retrace the concave shape of the trays, maintaining optimal focal distance with a diode pointer. Given that anti-reflective coatings are composed of metal oxides and chemicals, their ablation can release toxic elements, posing an inhalation hazard. To mitigate this risk, a fume extractor inside the fully enclosed workcell was activated to filter the air and capture harmful particles. A high-power pulsed fiber laser, equipped with an optic isolator to prevent back-reflection damage from the highly reflective stainless steel trays, was utilized. This semi-automated process was programmed once, allowing the cobot to repeat the cleaning procedure for subsequent trays, resulting in pristine lens holder trays ready for immediate use.
In the demo below, you can watch the CTIR-6040 in action and see the speed of the lens holder tray cleaning process:
What the CTIR-6040 Can Do for You
Laser Photonics offers laser cleaning systems as a safer, more environmentally friendly alternative to traditional surface preparation methods such as abrasive blasting, chemical treatment, and power grinding, which come with numerous drawbacks. In contrast to these methods, laser cleaning offers multiple benefits, while automation with collaborative robotics inside an enclosed workcell takes the technology a step further, reducing errors and minimizing the risk of radiation exposure.
To sum up the benefits you get with the CTIR-6040:
- Time Savings – fast and efficient results
- Labor Savings – limited human operator involvement
- Increased Throughput – speedy simultaneous processing of parts
- Repeatability – programming memory
- Precision – pinpoint accuracy and minimized error
- Consistency – same results, every time
- Multi-Functionality – cleaning, conditioning
- Reduced Consumable Costs – no use of consumables
- Minimized Material Loss – no damage to underlying substrate
- Customization – custom-tailored design to fit your needs
- Workplace Safety – no use of hazardous agents; isolated processing
- Eco-Friendliness – no hazardous waste or pollution
- Extended Lifespan – prolonged use of valuable components
The CTIR-6040 became commercially available in early 2024, with ongoing enhancements like overheat protection and mobile connectivity. For public sector procurement, we offer the system with TAA-compliant components through our defense-focused affiliate, Fonon Technologies. As Laser Photonics strives for continuous innovation, we next plan to integrate AI-powered data collection and recognition systems to further automate the processing of complex geometries, aiming to reduce human involvement and further simplify the operation. To learn more about how the CTIR-6040 can optimize surface preparation in your manufacturing processes, contact us today.
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