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Easy system design, compactness and a uniform power distribution define the basic advantages of high power VCSEL systems. Full addressability in space and time add new dimensions for optimization and enable "digital photonic production". Many thermal processes benefit from the improved control i.e. heat is applied exactly where and when it is needed. The compact VCSEL systems can be integrated into most manufacturing equipment, replacing batch processes using large furnaces and reducing energy consumption. This paper will present how recent technological development of high power VCSEL systems will extend efficiency and flexibility of thermal processes and replace not only laser systems, lamps and furnaces but enable new ways of production.High power VCSEL systems are made from many VCSEL chips, each comprising thousands of low power VCSELs. Systems scalable in power from watts to multiple ten kilowatts and with various form factors utilize a common modular building block concept. Designs for reliable high power VCSEL arrays and systems can be developed and tested on each building block level and benefit from the low power density and excellent reliability of the VCSELs. Furthermore advanced assembly concepts aim to reduce the number of individual processes and components and make the whole system even more simple and reliable.

Thermal treatment may be by far the most frequent process used in manufacturing, but only at a few places lasers could make an inroad. For thermal treatment, homogeneous illumination of large areas at a lower brightness, and accurate temporal as well as spatial control of the power is required. This is complicated for conventional high-power lasers, while vertical-cavity surface emitting laser-diode (VCSEL) arrays inherently have these capabilities. Because of their fast switching capability and low power dissipation, VCSELs have been widely used for datacom and sensing applications. By forming large-area arrays with hundreds of VCSELs per mm2, their use can be further expanded to high-power applications. In this way, power densities of several W/mm2 are achieved, making the VCEL arrays an ideal solution for many heating applications, ranging from melting and welding of plastics and laminates to curing, drying, and sintering of coatings. A turn-key system concept has been developed allowing fast and easy configuring systems to the specifications of the applications. The compact and robust system can be built directly into the manufacturing equipment, thus making expensive fibers and homogenizing optics superfluous. These systems are now finding their first inroads into industrial applications and have been designed-in into commercially available production machines.

Linear and nonlinear gain characterization of electrically pumped vertical external cavity surface emitting lasers (EP-VECSELs) is presented with spectrally resolved measurements of the gain and with gain saturation measurements of two EP-VECSEL samples with different field enhancement in the quantum-well gain layers. The spectral bandwidth, small-signal gain and saturation fluence of the devices are compared. Using the sample with the larger bandwidth, we have demonstrated the shortest pulses generated from a passively modelocked EP-VECSEL to date. With a low-saturation-fluence SESAM for passive modelocking we have achieved 9.5-ps pulses with 7.6 mW average output power at a repetition rate of 1.4 GHz. With a higher output coupler transmission the pulse duration was increased to 31 ps with an average output power of 13.6 mW. The pulses were chirped mainly due to the group delay dispersion (GDD) introduced by the intermediate DBR, which compensates the optical loss in the structure.

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