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It is a huge technical and engineering challenge to realize the precise assembly of thousands of large optics in high power solid-state laser system. Using the 400-mm aperture-sized transport mirror as a case, this paper aims to present an intelligent numerical computation methodology for mounting performance analysis and modeling of large optics in a high-power laser system for inertial confinement fusion (ICF).

Fundamental principles of modeling and analysis of the transport mirror surface distortion are proposed, and a genetic algorithm-based computation framework is proposed to evaluate and optimize the assembly and mounting performance of large laser optics.

The stringent specifications of large ICF optics place very tight constraints upon the transport mirror’s assembly and mounts. The operational requirements on surface distortion [peak-to-valley and root mean square (RMS)] can be met as it is appropriately assembled by the close loop of assembly-inspection-optimization-fastening. In the end, the experimental study validates the reliability and effectiveness of the transport mirror mounting method.

In the assembly design and mounting performance evaluation of large laser optics, the whole study has the advantages of accurate evaluation and intelligent optimization on nano-level optical surface distortion, which provides a fundamental methodology for precise assembly and mounting of large ICF optics.

Laser systems are becoming more and more a commodity in many fields of application and this is driving a strong trend towards increasingly efficient production technologies and miniaturized products. A central aspect of laser production is the assembly where the majority of cost is due to manual operations. Resistance soldering of optical components is an upcoming technology for automated assembly, especially for high power laser applications. This technology transfers design and packaging concepts from the electronics industry into photonics. The purpose of this paper is to present recent developments in the field of this soldering technology and to show the first experimental results in combination with robot‐based handling.

Soldering results were examined by resistance measurements, shear testing and optical analysis of the melting zone.

The experiments conducted proved the viability of robot‐based automated resistance soldering of optical components. Analyses of current and voltage profiles gave valuable information for process control possibilities without additional sensors and validated the theoretical considerations of the temperature dependency of material properties. Shear testing underlined the necessity for accurate mechanical contact arrangement and opened fields for further process developments.

Robot‐based resistance soldering of optical components represents a promising joining technology for the automated assembly of laser systems. Existing solutions with mechanical fixtures hamper the miniaturization of optical systems and concurrently increase material and production costs. Manual and semi‐automated gluing of components is an alternative process with significant disadvantages regarding the robustness of the process and the resulting joint connection.

DESPITE having worked in the Aircraft Industry for many years, I had never considered the importance of connectors to the operational efficiency of aircraft. That is, until one dark night when I was driving back into London along the M4 motorway, in the centre lane, at a steady 70mph cruise, the engine suddenly stopped. I declutched, disengaged the gear and coasted on, looking for a gap in the nearside traffic to reach the hard shoulder. When I tried to signal left I realised I had suffered a total electrical failure. After a cold wait the AA man came to my rescue, pulled the loom of wires from the engine bulkhead, cleaned up the pins and replaced it. The engine, lights and indicators sprang back into life. I learned about connectors that night!

Directed energy deposition (DED) with laser powder-feed is an additive manufacturing process that is used to produce metallic components by simultaneously providing a supply of energy from a laser and mass from a powder aerosol. The breadth of alloys used in DED is currently limited to a very small range as compared to wrought or cast alloys. The purpose of this paper is to develop the new alloys for DED is limited because current models to predict operational processing parameters are computationally expensive and trial-and-error based experiments are both expensive and time-consuming.

In this research, an agile DED model is presented to predict the geometry produced by a single layer deposit.

The utility of the model is demonstrated for type 304 L stainless steel and the significance of the predicted deposition regimes is discussed. The proposed model incorporates concepts from heat transfer, welding and laser cladding; and integrates them with experimental fits and physical models that are relevant to DED.

The utility of the model is demonstrated for type 304 L stainless steel and the significance of the predicted deposition regimes is discussed.

A report on three major American automation shows where innovative products and automated assembly technologies formed a focus. Products reviewed include grippers, actuators, assembly modules, dispensing controller and pneumatic components from a number of suppliers.

This paper presents a concept for a micro‐assembly station and shows different possibilities for increasing the positioning accuracy. The main part of the station consists of a spatial parallel structure with three translational degrees of freedom. An additional rotational axis is integrated into the working platform. This structure is constructed with low friction joints, which are nearly free of backlash. The construction of these high precision joints is presented and the characteristics of the robot such as workspace and resolution are discussed. After this an approach for increasing the accuracy of parallel robots by integrating flexure hinges into the structure is described.

Anicon, Inc. have recently appointed Friedrich Weiler as Managing Director, Anicon Europa, GmbH, and have announced the opening of Anicon's European headquarters facility in Munich.

The advent of low cost miniature solid state cameras now makes eye‐in‐hand robot vision a practical possibility. This paper discusses the advantages of eye‐in‐hand vision and shows that with the Unimation VAL operating system it is easier to use than is possible with static overhead cameras.