Choosing the Right LED Wavelength 

Selecting the appropriate wavelength is a pivotal aspect in maximizing the efficiency of UV LED curing systems. While we covered wavelength selection in the previous blog, let’s explore this topic from a different perspective, focusing on how it directly impacts the efficiency of the curing process. 

Enhanced Curing Performance 

The right LED wavelength significantly contributes to faster and more efficient curing. By selecting the optimal wavelength, you can decrease curing time and improve the overall quality of the cure, ultimately maximizing efficiency. 

Customization and Optimization 

UV LED sources offer system designers the advantage of working with specific wavelengths or multiple wavelengths, allowing for greater customization and optimization of the curing system. This flexibility enables system designers to fine-tune the curing process to specific materials and applications, optimizing efficiency. 

Multi-Wavelength Systems 

In certain cases, the use of multi-wavelength systems can provide enhanced flexibility and efficiency. By incorporating various wavelengths, you can effectively address diverse curing needs, streamlining production processes and maximizing overall efficiency. 

Material Compatibility 

Matching the absorption characteristics of the materials with the appropriate wavelength ensures optimal energy transfer, maximizing efficiency and reducing energy waste. 

Proper LED Placement 

LED technology is fundamentally a more compact technology than traditional lamps due to the LED packing densities possible. A variety of LED array methods such as through hole (T-pack), surface mount or chip-on-board can be implemented for different LED packing densities. 

ProPhotonix utilizes Chip-on-Board LED technology in which the bare chip is placed in direct contact with the substrate allowing greater design flexibility, greater intensity and uniformity. For example, LED substrates can be designed on flexible substrates, spherical substrates or as in the COBRA Cure FX series, the LEDs can be placed with an asymmetric distribution so that a higher distribution of LEDs is located near the edges of a lamp to mitigate shadowing effects which also results in higher intensity. 

Optimal Cooling 

UV LED lamps typically require fan or water-cooled systems to guarantee reliable continuous operation over the entire operating temperature range although some low power lamps are available that rely solely on convection cooling. Fan– cooled systems do not require any ancillary equipment, but higher intensity fan-cooled systems may become bulky due to the requirement for bigger and/or more fans to regulate the temperature.  

In environments where there are airborne particulates, filters can be attached to the lamp’s openings to reduce the access of these particles into the inner workings of the UV LED lamp. ProPhotonix offers a range of direct air-cooled UV LED systems with the COBRA Cure FX series. 

Effective Optics 

Optical design of UV LED curing systems is important to ensure that your system works efficiently and that all of the output generated by the UV LED system reaches the target material and cures the correct surface area. If the optical design of the UV lamp is not optimized, under-curing or over-curing can occur. For example, in print applications, if the ink is over-cured, the process results could be banding and other issues. Conversely, inefficient design or poorly fitted optics can result in a significantly reduced light output onto the target area resulting in under-curing of the target material. 

Optical requirements can differ from one application to another. For this reason, ProPhotonix has an in-house optical engineering team that can develop an optimized illumination system to satisfy your requirements. 

Controlled Irradiance 

An inherent challenge with LED curing systems is to maintain the high irradiance over working distances due to the divergence of light from the LED source. Measurement of irradiance is essential in order to optimize cure conditions and maintain consistency in cure results. By implementing techniques to overcome light divergence, optimizing optical design, and utilizing dynamic power control, engineers and system designers can achieve consistent and controlled irradiance levels.  

Regular Maintenance 

UV LEDs do not generate excess heat and as such are a “cool” cure technology ideal for curing materials on heat-sensitive substrates such as wood or plastics that might be damaged by the high temperatures generated from traditional mercury lamps. Maintenance downtimes and the costs involved will be lower because of the extended life of LEDs providing less production downtime versus the changeout required by mercury lamps.  

Conclusion 

Operating efficiency of UV LED curing systems is improved as a result of the unique control capability of light uniformity, speed of flash and precise spectral output among other factors. Following several years of research and customer trials, ProPhotonix launched the COBRA Cure FX series. The product range, designed specifically for UV curing of inks, coatings, and adhesives, offers the flexibility to configure a UV LED curing system to specific application needs.  

It is important to remember that the inherent advantages of UV LED curing systems over traditional UV lamps are not only about improved performance and higher efficiency but also about environmental friendliness and safety. Our next blog post will dive deeper into the safety measures for UV LED curing systems. With 15 years of experience in UV LEDs, ProPhotonix’ UV LED Curing systems can help maximize system performance. We have also worked with customers to design and produce custom UV LED solutions for more than two decades. 

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Key Features

• Now available in UV (375nm)
• Available wavelengths include 375nm, 405nm, 488nm, 520nm, 635nm, and 830nm
• Optical output powers from 10mW to 70mW
• Elliptical and circular beam, line generating, and diffractive optics available
• Reliable, Compact & self-contained design
• Adjustable optics and enhanced boresight options
• CW or TTL modulation options
• Available with a 25mm mounting flange

Key UV Laser Applications

The UV Photon laser is suitable for UV curing applications that require UV light focused on a smaller area than with UV LED technology. UV lasers offer very fast curing, and 3D Printing applications, many of which currently use 405nm light, could benefit from this compact UV laser. In particle analysis, this laser has the potential to take these applications to another level. The shorter wavelength may enable even smaller particles to be detected and measured.

A Proven Laser Module Platform

With many thousands of Photon laser modules operating in the field, the Photon laser modules are reliable and with a wide range of optical and CW or modulation options, they are configurable to address a wide range of applications. Now available with adjustable optics as well as an enhanced boresight option, the compact laser modules offer easy integration either as a final product or as an evaluation product should you need to validate laser technology within your system.

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New Wavelengths Added

The established PROdigii digital laser module can now be offered with the following wavelengths: 375nm, 405nm laser, 450nm, 905nm, and 940nm. These additional wavelengths in UV, blue, and IR mean that the functionality packed PROdigii can address many additional applications. The 375nm UV digital laser module is suitable for UV curing applications. The blue 405nm digital laser is ideal for both 3D printing and particle measurement. The new 450nm laser is well suited to spectroscopy applications. The additional infrared wavelengths, 905nm and 950nm, make the PROdigii an ideal solution in robotics and gesture recognition as well as LiDAR applications.

The PROdigii Digital Laser Module Range

The PROdigii digital laser module delivers high performance, stability, and control even in challenging operating environments. The new wavelengths are available in addition to the existing 520nm, 638nm, 660nm, and 808nm options. It has a compact cylindrical form factor and is configurable to your application needs. It is offered with output powers up to 500mW CW, 1W pulsed, and various diffractive options including uniform line and elliptical spot. The PROdigii uses a digital RS485 communication interface which provides intelligent control and monitoring. In addition to the applications mentioned above, 3D measurement, high precision alignment, chemical, and biomedical analysis as well as high speed automated inspection will benefit from the high -performance, monitoring, and control offered by PROdigii.

Key Features

• Wavelengths: 375nm, 405nm, 450nm, 520nm, 638nm, 660nm, 808nm, 905nm, 940nm
• Compact, high performance, digital laser module
• RS485 intelligent control and monitoring
• Integral thermal management
• Uniform line, elliptical sport or diffractive patterns available
• Output power up to 500mW (CW); 1W (pulsed)

Benefits of Digital Laser Modules

Digital laser modules are most useful for applications that require enhanced control and monitoring functionality. Often an existing system will also have another digital component, in which case having one control system for all elements is key as it keeps the design concise and increases ease of use. One benefit of using a digital interface is output power control, which leads to enhanced laser diode life. Digital monitoring also allows for preventative maintenance to be scheduled rather than relying on the reactive repair. You can learn more about digital interfaces in our previous blog post on “The Benefits of a Digital Laser Module”.

PROdigii Digital Laser Interface

Thermal Management

Thermal management is another benefit of PROdigii digital laser modules. To prevent heat damage, a thermal pathway is needed to ensure heat flows away from the laser diode when lasing. In the PROdigii laser module, a Peltier thermo-electric cooling device (TEC), which is built into the compact form factor, is used to pump out the heat. The superior thermal management provides exceptional wavelength stability and makes the PROdigii ideal for use in challenging operating environments. You can learn more about thermal management in laser modules in our previous blog post “Thermal Management in Compact, High Power Laser Modules”.

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Compact, Light Form Factor – No Compromise on Performance

With COBRA Cure Mini, ProPhotonix has utilized its expertise in Chip-on-Board LED array design and mechanical engineering to deliver the optimum solution for applications where space and weight are restricted but higher intensity and dose levels are required. COBRA Cure Mini’s light head measures just 33.4mm x 57mm x 30mm (1.3” x 2.24” x 1.18”), with control electronics housed separately achieving a compact light-head module. Weighing less than 175gm (0.4 lb) the light-head is suitable for compact translation systems, providing ease of installation without any compromise on performance.

Maximized Intensity and Dose

In addition to its compact form factor, COBRA Cure Mini delivers extremely uniform, high-intensity UV light for a reliable cure. It has been designed to deliver maximum intensity and dose offering the high performance of our COBRA Cure FX1 UV lamp in a more compact package. COBRA Cure Mini delivers intensities up to 6W/cm² and a factory set dose of up to 9 J/cm² at 2mm offering users the flexibility to meet weight restrictions and available footprint without any performance trade-off.

Key Features: Compact (33.4 x 57 x 30mm) Form Factor Weight: <175g Intensities: Up to 6W/cm² at 2mm Dose: 9J/cm² at 2mm Illumination Area: 36 mm x 13.5mm Linear Intensity Control Options

Key Applications

• UV Curing of:
  • Inks
  • Coatings
  • Adhesives
• 3D Printing

In-house Engineering and Manufacturing

ProPhotonix builds the light engine used to power the COBRA Cure FX series in-house and has engineered each step of the design and manufacturing process to ensure that intensity, dose as well as lifetime are maximized in the COBRA Cure Mini.

Applications

COBRA Cure Mini offers an ideal solution for UV curing of inks, coatings and adhesives as well as 3D printing applications. In high-speed single and multi-pass printers, COBRA Cure Mini can minimize infrastructure requirements and contribute to system speed and delivering the high performance required by these applications.

The post New Compact, Low-Weight, UV LED Curing System appeared first on Prophotonix.

Intensity and Dose

COBRA Cure FX1 Max delivers intensities up to 6.4W/cm² and a factory-set dose of up to 7.8J/cm². This increased output has been achieved without any increase in the compact form factor design of COBRA Cure FX1. The charts below show the comparable intensity levels, at different working distances, for both the COBRA Cure FX1 and the new COBRA Cure FX1 Max lamps.

ProPhotonix utilizes Chip-on-Board LED technology in its COBRA Cure FX Series. Using this LED packaging method, ProPhotonix works with the bare LED chip to design and manufacture densely packaged LED arrays. With this latest release, ProPhotonix has utilized its expertise in Chip-on-Board LED array design and packaging to deliver the optimum solution for applications where space is restricted but higher intensity and dose levels are required.

A number of intensity profiles are available with the COBRA Cure FX1 Max. Read this post for more information on intensity profiles.

Form Factor

In many applications, space is a premium. At just 77 X 28 X 120mm, COBRA Cure FX1 Max retains the slim and compact footprint of COBRA Cure FX1 making it well suited to applications with limited available area.

Benefits of a UV LED Curing System

UV LED curing systems offer a more sustainable solution than traditional technologies with no mercury content or ozone emissions. Operational costs are lower as UV LED systems offer longer lifetimes, significant energy savings, and less downtime for maintenance. If you need a curing system for thin films or heat sensitive substrates, a UV LED solution may be preferable due to its cold cure technology.

Lifetime

ProPhotonix understands the importance of product lifetime, as one of the key advantages of selecting a UV LED Curing system, in ensuring repeatable performance in your system.  The Optical, Mechanical and Electronic engineers at ProPhotonix developed and optimized the design and manufacturing processes increasing the COBRA Cure FX1 Max’ intensity and dose without compromising on lifetime.

Applications

COBRA Cure FX1 Max’ combination of higher intensity and dose, as well as a compact form factor, make it ideal for UV curing in printing and 3D Printing applications as well as UV curing of coatings and adhesives.

For more information about the COBRA Cure FX1 Max:

Download the Datasheet

About the COBRA Cure FX Series

ProPhotonix has a long history of working with OEMs to provide optimized LED solutions for their systems and more than 15 years of experience working with UV LEDs. The COBRA Cure FX series incorporates this wealth of experience offering reliably, high performance along with ease of installation a number of unique features. Learn more about the COBRA Cure FX Series.

The COBRA Cure FX Series has been designed with multiple mounting options allowing the lamps to be set to the optimum working distance for the application. The COBRA Cure FX1 series is UL, CE and IEC certified.

The post New Compact High-Power UV LED Curing Lamp appeared first on Prophotonix.

The Blue and Violet Laser Diode Range Overview

Blue and violet semiconductor laser diodes have commercial benefits, as well as technical benefits, as they offer a competitive alternative to DPSS lasers and other technologies currently available at these wavelengths.

ProPhotonix offers blue laser diodes at 450nm and 488nm with power levels up to 120mW. These blue laser diodes are manufactured by Osram, a company renowned for its innovation and focus on quality. Two package options are available at 3.8mm and 5.6mm. Osram blue laser diodes offer high reliability and long lifetimes.

Violet laser diodes are available at 404nm and 405nm with power levels from 12 to 1000mW. ProPhotonix supplies a range of violet laser diode solutions from Ushio, a company with more than 30 years of experience in the design and manufacture of laser diode technology as well as Ondax, known for its innovative wavelength stabilized laser diodes.

Violet laser diodes are available in a range of packages including 5.6mm and 9mm cans as well as a number of pin configurations to suit your application. These diodes can operate at a range of temperatures with operating temperatures for some up to a maximum of 70°C.

Blue and Violet Laser Diode Applications

Blue laser diodes can provide an ideal solution for demanding applications such as flow cytometry, medical diagnostics, DNA sequencing, bio-fluorescence, and particle measurement. Additionally, these laser diodes are suited to commercial applications including laser projection, stage lighting, biomedical applications, and metrology.

Violet laser diodes offer an excellent solution for applications such as medical and biomedical, measurement, and 3D printing.

Why ProPhotonix

With more than 20 years’ experience as both a supplier and an integrator of laser diodes, ProPhotonix has the expertise to help you in selecting the right laser diode for your specific application. Our relationships with laser diode manufacturers give us access to the latest in laser diode technology and ensure that we can deliver excellent value to you.

To learn more about the ProPhotonix laser diode range visit the blue laser diodes or violet laser diodes.

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Optical Design of UV LED Curing Systems

Optical design of UV LED curing systems is important to ensure that your system works efficiently and that all of the output generated by the UV LED system reaches the target material and cures the correct surface area. If the optical design of the UV lamp is not optimized, under-curing or over-curing can occur. Poorly designed optics placed in a UV LED curing system can result in unnecessarily high intensity causing over-curing of the target. Over-curing of target materials affects the quality of the final product. For example, in print applications, if the ink is over-cured, the process results could be banding and other issues. Conversely, inefficient design or poorly fitted optics can result in a significantly reduced light output onto the target area resulting in under-curing of the target material.

Greater intensity is not always the goal with UV LED curing systems, but the direction of light and dose (energy density) are critical. As a result, it is important to have the optimum optical design for your application and to ensure that you work with a reputable lamp supplier with a rigorous quality management system in place.

Supplier Expertise

Achieving the optimum energy density in each application is a challenge for UV LED curing systems designers. If energy density is too high the material will be over-cured, too low and the material will not cure consistently if at all. For system designers, the first step is to determine the optimum energy density for your application.

A further challenge in optical design is in material selection. Exposure to such high levels of UV light can degrade traditional materials over time, reducing optical output. ProPhotonix has over 10 years of experience in supplying UV LED based systems and has a well-established, reliable supply chain. Our extensive quality control, lifetime testing and burn-in facilities ensure repeatable, quality UV solutions.

UV LED Systems Optical Options

Optical requirements can differ from one application to another. For this reason, ProPhotonix has built flexibility into the design of our UV LED systems. Each product in the COBRA Cure FX series is configurable allowing users to select the optimum optical set-up for their application.

The COBRA Cure FX series is available in highly collimated, angle reduced and natural emission profile configurations. The highly collimated version is typically a zero degree option. This configuration has a narrow illumination angle, which ensures low risk of curing at the print head. However, this configuration is not suitable for applications that require a wide curing profile.

An angle reduced profile is the second option. This configuration provides an optical output angle of forty degrees. While still a relatively narrow illumination angle ensuring low risk of curing at the print head, this option produces high dose levels and is suited to applications requiring a wide curing profile. The angle reduced profile is a popular option, as it provides a tighter angle than many systems, which results in reduced reflections in the system and significantly reducing the risk of unintended curing. As this configuration maintains high intensity levels, especially over wide working distance ranges, it is ideal for applications such as inkjet printing.

The final option is a natural emission profile which offers a sixty degree angle. This configuration has the highest level of dose at short working distances (<5mm) of the options presented in this post, but dose reduces significantly past 5mm. With a wider illumination angle there is an increased risk of curing at the print head. The type of system can be used in industrial applications such as ink curing, counterfeit detection and medical applications.

ProPhotonix Experience

ProPhotonix has over 15 years of experience working with UV LEDs. As an experienced LED system manufacturer, ProPhotonix is expert in working with complex requirements to provide the optimum solution for your system’s needs. Custom solutions are also available where we can adapt many of our existing systems to meet your specific requirements. For these types of applications, ProPhotonix has an in-house optical engineering team that can develop an optimized illumination system to satisfy your requirements.

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3D Printing Requirements for Laser Diode Modules

Wavelength, optical performance and reliability are critical considerations when specifying a laser module for 3D printing applications. Wavelength requirements can be determined by the material being used as well as system requirements. As a laser diode supplier, as well as a laser module manufacturer, ProPhotonix has access to a wide variety of wavelengths, from a range of high quality manufacturers, making optimum wavelength selection for each application a shorter and more straightforward process.

In 3D printers, laser modules must perform repeatably and reliably. For these types of applications, the laser module manufacturer’s ability to deliver to tight specifications time and time again is crucial. ProPhotonix manufactures many of its parts in-house allowing the Company to deliver products to tight tolerances. In addition, the laser module manufacturer conducts extensive testing to ensure the laser diode modules perform consistently throughout their lifetime.

Stereolithography

Stereolithography is a 3D printing technique in which a UV light source is used to cure successive layers of liquid to turn it into hardened plastic in the shape of your required item. This vat process is also known as additive manufacturing and is typically used with computer aided design programs to produce prototypes.

3D Scanning

3D scanning is typically carried out utilizing a laser and a sensor together. These systems allow the user to capture the properties of the item being scanned and replicate it using a 3D printer. Laser diode modules have become the preferred technology in 3D scanning due to the availability of compact form factors, wavelength and power considerations, as well as optical performance and repeatability. ProPhotonix has developed a number of compact, cost effective laser modules for 3D scanning applications.

ProPhotonix Laser Module Expertise

As the market for 3D printing equipment continues to grow, ProPhotonix has developed strong relationships with leading 3D printer and scanner manufacturers worldwide due to the company’s comprehensive cost effective laser module offering. To learn more about ProPhotonix expertise in 3D printing applications

Download the case study

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