The Need
Industrial high-energy lasers, commonly used in welding, metal additive manufacturing, and cutting, require precise beam profiling to optimize performance and ensure quality. However, current commercial beam profiling systems are prohibitively expensive or incompatible with high-power lasers due to sensor damage thresholds and spatial constraints near the focal plane. There is a critical need for a cost-effective, high-resolution solution capable of operating safely and accurately in these high-power environments.

The Technology
This innovative system enables safe, high-resolution measurement of industrial high-energy laser beam profiles using a compact and cost-effective approach. It overcomes the limitations of conventional profiling tools by integrating a novel optical configuration that accommodates high power levels and short working distances. The design allows for detailed beam characterization at or near the focal plane, making it suitable for a wide range of industrial and research applications involving powerful laser systems.

Commercial Applications
• Directed Energy Deposition metal additive manufacturing
• Industrial laser welding and cutting systems
• Laser system calibration and diagnostics
• Research and development of custom laser beam shapes
• Quality assurance in laser-based manufacturing

Benefits/Advantages
• Compatible with high-power lasers (up to 2000 W)
• 85–90% lower cost than commercial alternatives
• Enables beam profiling at short focal lengths
• Provides high-resolution, magnified beam profiles
• Reveals power-dependent focal shifts, improving modeling accuracy
• Real-time, in-line profiling