Optimizing the Laser Beam Spot Size for Laser-assisted Manufacturing Applications

This project focuses on modeling and analyzing different lens combinations and design parameters to optimize laser beam spot formation on a small material surface using Ansys OpticStudio software. The approach involved defining key parameters such as aperture, focal length, and lens thickness, to form a beam spot. A Gaussian heat source modeled the helium-neon laser beam, considering both continuous and pulsed laser modes. Various designs were modeled to determine the ideal aperture and lens curvature for optimal beam spot formation. The merit function was employed to automatically refine lens parameters, achieving an IMA of $\mathbf{1. 0 7 6 ~ m m}$ with a 25 mm aperture. Laser heating has potential applications in semiconductor manufacturing, nanotechnology, and precision engineering. This project thus offers valuable insights for advancing material processing techniques, enabling precise micro- and nanoscale fabrication.