The most filigree structure made by remote laser cutting

Abstract

It is well known that the global climate change is the largest challenge for the society of the 21th century. In order for us to manage the resulting consequences, innovative materials for energy efficient applications become more and more important. Open cell metal foam contributes promising solutions to the light weight design, battery applications and renewable energy harvesting. Still, challenges are present concerning the cutting into a defined shape. The remote laser cutting offers a solution for decreasing the production costs as well as the needed component accuracy. Our investigations consider that this technique has a high potential concerning cutting speed which was increased by more than 500 %, compared to state of the art laser separation. Next to that, the contour accuracy was improved as well, resulting in tolerances with less than 30 μm. Together with the forceless process of remote laser cutting, the possibility is given to generate filigree components with a wall thickness less than 0.75 pore sizes. This paper offers insight into the viability of remote laser cutting in overcoming the challenges dealing with mechanical milling or grinding. Investigating the process concerning thermal stress input as well as particle attachments will be the next steps in the future.