Flexishaper DOEs can easily be installed into off-the-shelf manual or motorized rotation mounts to create an optical module. This module can be integrated in multiple configurations into the optical axis requiring no high NA or other costly optics different from the standard laser welding optics. The Flexishaper™ pair can be used with both single mode and multi-mode lasers, and can be adapted for large beams typically used with multi-kW lasers, thus enabling a large range of macro and micro-welding processes.

Once the optimal ratio for the process has been found, the module can be replaced with a single static DOE tailored to generate the exact needed ratio, providing a cost-effective solution at larger machine series.

Flexishaper concept for Adjustable ring-to-spot shaping was first introduced by HOLO/OR in a scholary article on 2019. It was then improved to the rotational module form and released on 2021.

The module form was tested and validated in cooperation with HOLO/OR’s sister companies SCANLAB and BLACKBIRD for Single-Mode high-speed foil laser welding, producing an impressive increase of >30% in weld speed with up to 700W, and with potential to reach >55% increase with higher laser power approaching the 1 kW for welding an overlap of two 100 µm stainless steel sheets.