Girish P. Kelkar, Ph.D.

WJM Technologies (562) 743-7576

Laser Focus Spot Size Control

Interaction of a laser beam with any material is a function of energy density, which in
turn is a function of laser beam power and spot size. While laser power is easy to change
on the programming pendant/screen, changing the spot size takes more of an effort, and
in some cases, advanced planning. In this document, we will review various options to
reduce spot size and costs associated with such a change. Spot size can also be increased
by reversing the steps, but is not a common requirement.

Laser spot size can be calculated by the following formula (Equation 1):

Where,
d = spot diameter (microns)
λ = wavelength (microns)
f = focal length of the focus lens (cm)
M2 = Measure of beam quality (1 is ideal)
D = beam diameter coming into the focus lens (cm) [not the lens diameter]

Figure 1. Shows focusing of beam down to smallest spot size, d00, corresponding to an
ideal single mode beam (M2=1, TEM00).

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With suitable optics and excluding any lens errors, a 1-micron wavelength gaussian beam
(M2=1) can be focused down to a theoretical spot diameter of about 1 micron, which is
considered the absolute smallest spot size possible, also known as diffraction limited spot
size. In practice, lens errors and limitations to beam size and optical hardware will limit
the spot size to order of 10-30 microns. Such small spot sizes are commonly used for
cutting, marking, and drilling applications. Examples include stent cutting, 2D barcode
marking on practically anything, and drilling of fine holes for fuel injectors.

For applications where larger spot sizes are employed such as welding (50-500 microns),
good beam quality is not a major requirement. In such applications, energy is usually
delivered to a focus head through a fiber, core diameter of which is typically in the range
of 50-300 microns. The welding spot size is then essentially an image of the core
diameter (which can be changed by fiber selection), as seen in the schematic below.

Figure 2. Schematic shows the optical path of laser beam through the beam delivery
optics. If the collimator and focus lens are of the same focal length, then the spot size is
an image of the core diameter.

Based on simple optical imaging effect from your high-school physics text book, the spot
size can be defined as (Equation 2):
Spot size = Core Diameter x Focus Lens Focal Length / Collimator Focal Length

Depending on the application and optical hardware employed, different factors will come
into play in determining the spot size; those factors are discussed in the following
sections.

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Laser wavelength is fundamental property of the lasing atoms and is of the order of 1
micron for YAG and Fiber laser, and 10 microns for CO2 lasers. Wavelength can be
halved by sending the beam through a frequency-doubling crystal (as was implemented in
the patent on green welding laser) or even tripling or quadrupling crystal where the
wavelength is reduced to a third or fourth of original. The main reason for reducing
wavelength is to improve laser absorption to match the material being processed;
reduction in spot size is a secondary benefit. Changing wavelength by frequency
changing crystals is an expensive proposition as it involves the crystals themselves (and
replacement costs) as well as laser energy loss as the beam passes through the crystal.
The decision to use frequency changing crystals has to be made upfront as the laser has to
be configured accordingly; not a second thought option.

Spot size can also be reduced by installing a focus lens of shorter focal length. This
change is relatively easy in most focus heads, and is a common option in welding
applications. The downside of a shorter focal length is a shorter depth-of-focus (see
Figure 2. below), which is the distance along the optical axis where the spot size is
relatively unchanged. Shorter depth-of-focus raises the risk of the spot going out-of-
focus with minor changes in part shape or fixture variations. An out-of-focus spot will
have lower energy density and likelihood of insufficient weld depth.

Figure 2. Comparison of short and long focal lengths on depth of focus. Shorter focal
length lens will have smaller spot size and shorter depth-of-focus.

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Spot size can also be reduced by improving beam quality for cutting/marking/drilling
applications, and is measured by a factor referred to as M2. An ideal beam where the
energy distribution is perfectly gaussian has a M2 value of 1. To achieve an M2 of 1 in a
conventional YAG/Vanadate solid-state laser requires use of a very small diameter YAG
rod and/or a very small aperture in the resonating cavity; both methods limit the power
output. Fiber lasers are not so constrained and are able to produce good beam quality
even at high power levels of the order of multiple kW. Same is true with CO2 gas lasers
which have lost some of their market for welding applications to fiber lasers, but continue
to be popular for cutting applications. Even though beam quality is not an issue to
control spot size in welding applications, good beam quality allows fiber lasers to be
focused to a reasonable spot size at distances of the order of 200-1000 mm, greatly
expanding the scope and applications for laser welding including remote galvo-welding.

The last option to reduce spot size is to increase the beam diameter as the beam enters
the focusing lens. Beam diameter can be increased with beam expanders placed between
the collimating lens and focus lens. Increasing beam diameter reduces beam divergence
and allows beam to focused to a smaller spot size. This strategy is commonly used in
marking lasers to control spot size, but can also be used in welding lasers. The downside
is the added expense of beam expanders and the energy loss as the beam travels through
additional lenses.

Figure 3. Beam expander uses a combination of lenses to increases diameter of the

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With so many choices to produce the desired spot size, a laser engineer has to carefully
balance the pros and cons before choosing a particular strategy. Some of the options
have to be planned in advance as they are not easy to implement without suitable
hardware design. Engineers will do well to give spot size some serious thought, else the
process will put them on the spot!

If you have any questions about the contents of this newsletter or any other question
about welding, please contact us at WJM Technologies.

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