DUAL LASER MACHINE SYSTEM SPECIFICATIONS

# System Overview

This system must be a dual laser configuration using a tripled UV:YAG
laser (7-watt output at 355-nm wavelength ) and 80-watt '9 micron' CO2
lasers. Both lasers will be mounted side by side on a rigid, Class 1
enclosed metal frame and each laser will have its own individual beam
delivery system including all optics.

The Dual Laser Machine System shall be furnished in accordance to the
following:

# Lasers

> The lasers shall be: 1.) An 80-watt sealed CO2 laser complete with
> power supplies, function generator, and control electronics line
> narrowed to 9.3-micron wavelength. The electronics must allow the
> operator to vary the pulse width and spacing.
>
> 2.) A 7-watt, 355nm wavelength, tripled frequency diode pumped solid
> state Nd:YAG laser complete with power supply and control electronics.

A water-to-air chiller for the CO2 laser shall be provided and be
capable of supplying cooling water in a re-circulating fashion. The
chiller must operate at 208 VAC, 60 Hz, at no more than 30 amps. Shall
be capable of dissipating at least 2.5 kW of heat energy while being
located at least 25 feet from the laser source.

Both lasers must be field serviceable after installation at NASA
Langley. This includes but not limited to laser refurbishment and
repair.

Both lasers must be specified for a minimum of 10,000 hours of operating
lifetime.

Both lasers must be commercially available and have a Center for Disease
and Radiological Health (CDRH) class IV rating.

# 

# Frame and Base

The frame shall be a heavy metal skeleton designed for vibrational
stability and ergonomic use.

A Class 1 enclosure with laser safe observation window, all access doors
and light paths sealed and interlocked, will provide safety for
operators and others in the room.

The table motion, lasers, beam delivery components and optics, support
gantries and structures, will rest on a granite base no less than 8
inches thick.

Rubber gaskets shall be used to attach metal components and supports to
the granite base.

All hollow support structures attached to granite base shall be foam
filled to reduce vibrational effects.

All laser, optics, and laser component support structures shall be
constructed of sturdy, extruded aluminum or granite.

Frame and base must pass through door opening of 79 inches in height and
71 inches in width.

The frame and base shall not exceed 80 inches in length, 60 inches in
width, and 78 inches in height due to space limitations.

The frame shall have a standard AC disconnect box for hardwiring system
to electric supply source.

The AC distribution box shall also control a 120-volt AC auxiliary
source of no less than 5 amps automatically turning ON when the system
is powered up and OFF when it is powered down. The 120-volt AC auxiliary
source shall also be controllable with the system software. This feature
is for the purpose of controlling an external filtration system to be
supplied by NASA.

Shall be provided with 2-inch ducting from the process area to outside
the cabinet via a flange with fitting to attach a 2-inch flex hose from
the external filter. This ducting must be rated to handle 250 scfm
(specific cubic feet per minute) \@24" WC (water column) and must not
interfere in any way with the operation of the system.

Shall be equipped with covers, guards, and other safety devices for all
parts of the machine that present safety hazards which do not interfere
with the operation of the machine. The covers shall be removable to
facilitate inspection, maintenance, and repair of parts.

# Beam Delivery

The beam delivery will consist of optics for the CO2 laser, which will
be side by side with the optics for the Nd:YAG laser, so that either may
be used with a shared motion platform and camera base.

The CO2 and UV:YAG lasers shall have fixed beam and galvanometer beam
delivery.

The CO2 laser fixed beam delivery shall be capable of pressurized and
localized [coaxial]{.underline} gas flow assist cutting. (Coaxial to the
laser beams.)

The lasers and beam deliveries shall be able to achieve the following
spot sizes:

CO2 laser:1.) Fixed beam shall be 50 microns or less

a.) Galvanometer shall be 200 microns or less

Nd:YAG: 2.) Fixed beam and galvanometer shall be 25 microns or less.

The changeover between galvanometer and fixed beam delivery shall be
automated and integrated with control software with a two-position hard
stop shuttle.

Galvanometer based beam delivery for both lasers shall have a minimum of
a 6-inch field.

All necessary optics, turning mirrors, and unmentioned beam delivery
components shall be included for the purpose of fixed and galvanometer
beam delivery for both wavelengths of lasers.

Optics will be provided at each laser wavelength for expanding the beam
through a telescope and for focusing to a tight spot. Beam expansion
into the final focusing lens will give the smallest diameter spot at the
target plane.

Each of the focus heads (for the CO2 laser and the Nd:YAG laser) will be
mounted on a motorized z-stage using an auto depth adjustment proximity
sensor for automatic height adjustment.

All optical paths will be enclosed for safety.

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# Platform and Motion Control

The X-axis platform travel shall be no less than 30 inches.

The Y-axis platform travel shall be no less than 24 inches.

The laser cutting area shall be no less than 24 inches x 18 inches
regardless of which focus head is used.

The X-Y axis platform shall be a ball screw, servo motor driven type and
equipped with glass scales.

The X-Y axis platform shall have mechanical and computer controlled
crash protection.

The Z-axis platform shall be separate from and perpendicular to the X
and Y- axis platform.

The Z-axis platform shall have a brake, a mechanical stop, and computer
controlled crash protection to prevent collision with the X-Y axis
platform.

The Z-axis platform shall be a ball screw, servo motor driven type and
have an auto depth control feature.

The Z-axis platform shall hold all lasers focusing heads and video
cameras.

The Z-axis and laser system shall accommodate and focus a cut on a part
up to 2 inches thick.

The Z-axis platform travel shall be no less than 4 inches.

The X, Y, and Z- axis platform motion shall have better than 5-micron
repeatability.

The X, Y, and Z- axis platform motion shall have at least + or -- 10
microns positioning accuracy.

The X, Y, and Z- axis platform motion shall be capable of rapid jog feed
rates in incremental and absolute commands.

The system shall be designed so any motion in any axis cannot collide
with any other axis or structure.

All axes shall be computer controlled with software package.

# Video system

A color video camera with up to 300x magnification and zoom will be
included.

This camera will be mounted in an off axis configuration and will have a
predetermined offset for each beam delivery head.

Part viewing will be done on the computer monitor using a video capture
board and color photos will be printable using normal computer printers.

# Software

The software shall be able to control the following:

a.  Shall have independent software control of both lasers ( only one
    laser is on at a time)

b.  Shall automatically control the speed of the platform motion based
    on the pulse spacing, limited by the laser's maximum pulse rate and
    by the platform maximum tracking speed.

c.  Pulse spacing shall be constant through acceleration, deceleration,
    and arcs.

d.  Shall control the table platform (X and Y) and an automated Z-stage.

e.  Shall control automated shuttle between fixed and galvanometer beams
    for either (or both) laser(s). See [Beam delivery]{.underline}
    section.

f.  Shall be capable of making corrections for stretch, shrink, and
    skew.

g.  Shall be able to adjust for rotational alignment and thermal
    expansion using at least two reference points on the part being
    machined.

# 

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h.  Shall display a warning if a change in reference points is detected.

i.  Shall be capable of adjusting program to compensate for alignment
    changes detected in part reference points.

j.  Laser fire is slaved to either galvanometer or table motions and can
    be switched on the fly.

k.  Shall be capable of running programs in manual and automatic modes.

l.  Shall be able to start program at any line number.

m.  Shall preview cutting pattern before running part. The plot shall be
    drawn in the same order as the part will be machined.

n.  Shall allow cutting path to be offset to either side or centered on
    the programmed line.

o.  Shall allow the operator to turn the laser on and off and to set
    values related to the lasers operation.

p.  Shall allow general configuration and tuning values to be stored in
    a configuration file that is read when application starts up.

q.  Shall be expandable to a minimum of 8 axes of motion.

The software will be Windows NT based and shall be designed for ease of
use (user friendly).

All software and video information shall be viewed on a single monitor
located at the control center. The control center shall be located in a
convenient location to the platform area.

Programs shall be entered via an edit screen or read from a file.

Implemented program functions shall have the [ability to and are not
limited to]{.underline} the following:

a.  Choose laser, set hole radius and spacing for cutting lines.

b.  Insert alignment fiducial point as described below.

c.  Move laser to specified X, Y, location.

d.  Cut a line from current location to a specified X, Y.

e.  Fire specified number of pulses at a given location.

f.  Cut a circle of radius R around point X, Y.

g.  Cut a segment of a circle.

h.  Radius a 90-degree corner.

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i.  Define the beginning of a pattern block.

j.  Repeat from the last Block N times with X, Y offsets.

k.  Pause specified number of milliseconds.

l.  Deleting and/or moving one or more program lines.

m.  Removing offsets from 0 in the X and Y-axes.

n.  Left/right mirror transformation.

o.  90 degree pattern rotation.

Coordinates shall be entered manually through direct typing input or
"taught" by moving the stage under the video camera.

Shall be capable of data entry in units of microns, millimeters, inches,
or mils and then translated for program use.

Software shall be able to interpret at minimum the following file
formats:

a.  HPGL Plotter File (PLT)

b.  Windows Enhanced Mate File (EMF)

c.  Windows Mate File (WMF)

d.  Windows Bitmap (BMP)

e.  JPEG Bitmaps (JPG)

f.  Compuserve Bitmap (GIF)

g.  Paintbrush (PCX)

h.  Trueview Job (JOB)

i.  Trueview Object (MCL)

j.  AutoCAD (DXF)

# Computer

Shall include, but not be limited to the following features:

1.  Shall have at least a 32-bit Pentium processor.

2.  Shall be capable of concurrent programming.

3.  Shall have at least a 4-gigabyte hard drive for mass data storage of
    programs for loading/downloading.

4.  Shall have at least one 3.5 inch, 1.44-MB floppy disk drive.

5.  Shall have at least 256-MB non-volatile RAM memory.

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6.  Shall be Internet capable for connection with T1 lines.

7.  Shall have CD-ROM drive.

8.  Shall operate Windows NT based.

9.  Computer shall be an industrial rack-mounted type.

10. Shall have a 15 inch minimum LCD color monitor, swing arm pod
    mounted, with keyboard and trackball.

11. Shall accept data inputs from an Internet source, manually via a
    keyboard, 3.5-inch IBM format floppy disk, CD ROM drive, or from
    internal computer assisted graphic programming software.

# Misc. Parameters

Shall be capable of operating on 208-volt, 60-hertz, single-phase power
at the site.

Shall have all operating controls necessary for manual and programmed
operation of the machine mounted for convenient operator access and
shall be clearly identified. All parts subject to wear, breakage, and
distortion shall be accessible for adjustment, replacement, and repair.

Shall be provided with a means to ensure adequate lubrication for all
moving parts. Each lubricant reservoir shall be identified by type of
lubricant and shall have a means for determining fluid levels. All
lubrication hole, grease fittings, and oil reservoirs shall be
accessible for service.

Shall have all words on plates, panels and charts in English language.
Characters shall be engraved, etched, embossed, or stamped in bold face
on a contrasting background.

The Contractor shall furnish with delivery of the machine Two sets of
operation, programming, and maintenance/wiring manuals. The contractor
shall also furnish all software information required to operate/program
the machine's computer control.

The Contractor shall, within thirty (30) days after date of contract
award, sufficient information to allow he Government to prepare the
site. The Government will bring the electrical and air service to within
five (5) feet of the installed laser system.

The Contractor shall install the laser system in building 1232A, Langley
Research Center, Hampton VA.

The Contractor shall, immediately after installation, demonstrate that
the Dual Laser Machine System is in accordance with the above
specifications. The Contractor shall also guarantee the equipment will
perform at this level of acceptance for a period of not less than 12
months from the completed installation date.

The Contractor shall provide all operators training and instruction
materials at the NASA site for at least two NASA employees. Training is
to be conducted by a qualified representative. Training will be
conducted Monday through Friday during NASA's normal working hours of
8:00am to 5:00pm Eastern Standard Time.

# Laser Machine System Options

The Contractor shall be able to provide NASA Langley Research Center
with the following options.

1.  Shall provide additional training upon request at a daily rate.

2.  Shall be able to provide air isolation dampening for the laser
    system if vibrational effects from external sources at NASA
    interfere with the operation of the laser system.

3.  Shall be able to provide extended service/maintenance contract
    within a one-year period of the delivery will include one or a
    combination of the elements outlined below.

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a.  A full maintenance/calibration/extended service contract
    guaranteeing a qualified technician at Langley Research Center
    within 72 hours of notification by NASA to repair/service the laser
    system.

b.  Provide maintenance/extended service at a daily rate.

c.  Provide system calibration service at a daily rate.

4.) Shall be able to provide vacuum chucks of various sizes.

# Past Performance