The use of femtosecond laser pulses allows precise and thermal-damage-free removal of material (ablation) with wide-ranging scientific, medical and industrial applications. However, its potential is limited by the low speeds at which material can be removed and the complexity of the associated laser technology. The complexity of the laser design arises from the need to overcome the high pulse energy threshold for efficient ablation. However, the use of more powerful lasers to increase the ablation rate results in unwanted effects such as shielding, saturation and collateral damage from heat accumulation at higher laser powers. Here we circumvent this limitation by exploiting ablation cooling, in analogy to a technique routinely used in aerospace engineering. We apply ultrafast successions (bursts) of laser pulses to ablate the target material before the residual heat deposited by previous pulses diffuses away from the processing region. Proof-of-principle experiments on various substrates demonstrate that extremely high repetition rates, which make ablation cooling possible, reduce the laser pulse energies needed for ablation and increase the efficiency of the removal process by an order of magnitude over previously used laser parameters. We also demonstrate the removal of brain tissue at two cubic millimetres per minute and dentine at three cubic millimetres per minute without any thermal damage to the bulk.

We demonstrate burst-mode operation of a polarization-maintaining Yb-doped fiber amplifier capable of generating 60 μJ pulses within bursts of 11 pulses with extremely uniform energy distribution facilitated by a novel feedback mechanism shaping the seed of the burst-mode amplifier. The burst energy can be scaled up to 1 mJ, comprising 25 pulses with 40 μJ average individual energy. The amplifier is synchronously pulse pumped to minimize amplified spontaneous emission between the bursts. Pulse propagation is entirely in fiber and fiber-integrated components until the grating compressor, which allows for highly robust operation. The burst repetition rate is set to 1 kHz and spacing between individual pulses is 10 ns. The 40 μJ pulses are externally compressible to a full width at half-maximum of 600 fs. However, due to the substantial pedestal of the compressed pulses, the effective pulse duration is longer, estimated to be 1.2 ps.

Thermal effects, which limit the average power, can be minimized by using low-doped, longer gain fibers, whereas the presence of nonlinear effects requires use of high-doped, shorter fibers to maximize the peak power. We propose the use of varying doping levels along the gain fiber to circumvent these opposing requirements. By analogy to dispersion management and nonlinearity management, we refer to this scheme as doping management. As a practical first implementation, we report on the development of a fiber laser-amplifier system, the last stage of which has a hybrid gain fiber composed of high-doped and low-doped Yb fibers. The amplifier generates 100 W at 100 MHz with pulse energy of 1 μJ. The seed source is a passively mode-locked fiber oscillator operating in the all-normal-dispersion regime. The amplifier comprises three stages, which are all-fiber-integrated, delivering 13 ps pulses at full power. By optionally placing a grating compressor after the first stage amplifier, chirp of the seed pulses can be controlled, which allows an extra degree of freedom in the interplay between dispersion and self-phase modulation. This way, the laser delivers 4.5 ps pulses with ~200 kW peak power directly from fiber, without using external pulse compression.

We report on a 72 W Yb all-fiber ultrafast laser system with 1.6 GHz intra-burst and 200 kHz burst repetition rate developed to demonstrate ablation-cooled material removal at high speeds. Up to 24 W is applied on Cu and Si samples with pulses of ∼300  fs, and record-high ablation efficiencies are obtained, compared to published results to date, despite using only ∼100  nJ pulses. Ablation speeds approaching 1  mm/s are reported with 24 W of average power, limited by available laser power and beam scanning speed. More significantly, these results experimentally confirm the theoretically expected linear scaling of the ablation-cooled regime to higher average powers without sacrificing efficiency, which implies that further scaling is possible with further increases in laser power and scanning speeds.

We report on an all-fiber Yb laser amplifier system with an intra-burst repetition rate of 3.5 GHz. The system is able to produce minimum of 15-ns long bursts containing approximately 50 pulses with a total energy of μ 215 J at a burst repetition rate of 1 kHz. The individual pulses are compressed down to the subpicosecond level. The seed signal from a 108 MHz fiber oscillator is converted to approximately 3.5 GHz by a multiplier consisting of six cascaded 50/50 couplers, and then amplified in ten stages. The highly cascaded amplification suppresses amplified spontaneous emission at low repetition rates. Nonlinear interactions between overlapping pulses within a burst is also discussed.