ENGINEERED BY CAMBRIDGE TECHNOLOGYFIREFLY3D 3-AXIS LASER SCAN HEAD DATA SHEETHIGHEST PRINTED PART QUALITY FOR LASERPOWDER BED FUSION WITH CLASS LEADINGPRODUCTIVITY
Novanta develops photonics solutions through our globally
recognized brands— Cambridge Technology, Laser Quantum
and Synrad— specializing in cutting-edge components, laser
controllers, software, and sub-systems for fine material processing,micromachining, and laser-based diagnostics and analytics.

DESIGNED AND BUILT TO MAXIMIZE
LPBF RESULTS AND PRODUCTIVITY

Ultra-fast scan head improves productivity - Advanced scan headdesign coupled with unique ScanMaster™ Controller features increase
throughput by as much as 10%, reducing cycle time.
Supreme accuracy optimizes surface quality and structural
integrity - Exacting laser spot placement and ultra-low drift delivers
class leading replication with 5- 10% reduction in long-run failures
and lowers post process requirements for FDA and FAA verification
metrology.

UNIQUE SCANNER/CONTROLLER/
SOFTWARE ECO-SYSTEM UNLOCKSUNMATCHED LPBF FEATURES

Built-in quality control - Two synchronized monitoring bands, realtime scanner data and an open sensor data stream enable immediate
processing feedback.
Radical calibration time reduction - Unique Automatic Scan
Field Calibration (ASFC) drastically reduces machine downtime forcalibration from 8+ hours to < 15 minutes. ASFC delivers up to 50%
more scan accuracy and eliminates the need for expensive metrology
equipment.
Faster, easier integration minimizes commissioning time - True
plug & play operation saves OEM integration costs with a IP65 rated
enclosure with certified optical performance at full power.

FIREFLY3D combined with Novanta ScanMaster™ Controller and
ScanMaster™ Designer software package creates a unique, industry
leading eco-system dedicated to maximizing output with extreme
processing detail. The new eco-system when finely tuned for
LPBF applications unleashes the power of an optimized additive
manufacturing system.
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BUILT FOR OPTIMAL LPBF RESULTS
Field proven Lightning™ II technology - state-of-the-art scan headdesign includes a high-speed, high-accuracy Dynamic Focusing
Module (DFM). Lightning™ II scan heads are primarily found in 3D LPBF
systems used for precision medical device applications.

Unmatched repeatability - 1 µrad RMS repeatability achievescommanded position at center and maximum scan angle, over 60
second interval. Industry leading repeatability ensures consistentprocessing results over long print runs, delivering a 5 – 10% reductionin scrapped parts.

60
Probability %40

2000.4Ultra-lightweight Beryllium mirrors - matched with digital galvosdeliver the fastest jump speed available in LPBF systems to reduce
layer processing time.

16-bit command accuracy

0.8

1.0

1.2

1.4

1.6

1.8

2.0µRad RMS Repeatability

Description

ShortRange

Working Distance (mm)2004506506501000

Field Size(mm)215 x 215

430 x 430

620 x 620

620 x 620

920 x 920

0.20

0.45

0.65

0.65

1.00

Repeatability(µm)

Industry leading 24-bit command protocol - delivers best-in-classprint replication with both 24-bit command data for greater position
accuracy, and 24-bit status data for hi-definition feedback of position,velocity, current, voltage, temperature and more.

0.6

Mid-Range

Long Range

Certified focus spot quality - each production unit is evaluatedusing PRIMES micro spot monitor in a fully automated test benchwith up to 1 KW laser power. Novanta optical certification processensures consistent delivery of laser power for unmatched density of
fused metal and part surface quality. Each FIREFLY3D is shipped with
its Optical Certification report. Novanta is the only laser scan head
supplier that provides full laser power acceptance testing.

24-bit command accuracy

Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

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2

BUILT FOR OPTIMAL LPBF RESULTS
Fully automated calibration system - simplifies the complex, timeconsuming calibration process and eliminates the need for expensive
metrology equipment. Machine downtime due to calibration is
reduced by as much as 90% and ensures a 5 µm feature accuracy
without the need for highly trained service personnel.

Superior Low Drift - precise and consistent laser beam placement
ensures consistent processing results of high-quality part surface
and density of fused metal. FIREFLY3D’s industry leading galvos are
field proven, exhibiting drift performance of less than 10 µrad over 8hours of operation after a 30-minute warm-up period.

The Automated Calibration System is a one-button solutionthat initiates the scanning of a laser-structured glass target andrecording back-reflected stray light with photo diodes. The systemthen correlates the photo diode signal with scanner coordinates.
The Automation Calibration software then automatically creates asystem correction file and the system is ready to use.
Automatically Binarized “Straylight Image”
-10

1-9.8

0.8

-9.6
0.6

Laser Scanner
Y-Coordinate-9.4
0.4-9.2

0.2-9-8.8Binarized
Magnitude(0 or 1)

-9.2

-9-8.8

-8.6

-8.4

-8.2

-8-7.80Laser Scanner X-Coordinate

Automated Calibration Laser Beam Path•

Laser On•Temperature is a critical part of maintaining low drift performance.
FIREFLY3D’s water cooling system can be enhanced with goodthermal management of the LPBF system. Temperature induced drift
is 10 µrad/K.
Laser Off

Automated Calibration Field Pattern Coverage

Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

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3

FASTER, EASIER INTEGRATION
High-band
optical monitoring
port, 1200 - 2000 nm

Quick disconnect coolingwater ports (DI-water +additive, maximum 100 µmparticles)

Pre-aligned processlaser interface adapter,
1050 – 1090 nm

Power monitor

High-speed
serial output (HSSO)

Diagnostics/legacy
support port
Power (48 VDC ± 2 VDC)

Process monitor
sensor input (PMSI)

Scan job communication(GSBX/XY2-100)

IP65 rated optical enclosureLow-band opticalmonitoring port (450 – 900 nm)
Laser Beam Exit

USER SUPPLIED COMPONENTS & OPEN ARCHITECTURE
The open platform design intentionally enables easy integration of the user’s sensing technology to address current and emerging in-processmonitoring needs. Synchronized real time scanner position and sensor data are connected to a feedback loop that controls the laser power.
Laptop/PCJobPreparation
High Band Port
(1200 - 2000 nm)

Gating, Modulations and Power Control
Customer
Process Sensors& Analysis

Process Data Router(X, Y, Z scan headaxes, Sensor 1 & 2)

Laser
Power Monitor

Scan HeadCorrective Signal

Vector Dataand Process
Parameter
Set-Points(Power,Speed, etc.)

Process Control
Logic
Scan Controller

Low Band Port(400 - 950 nm)
Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without noticeTarget Material

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4SCANMASTER™ CONTROLLER & SCANMASTER™ DESIGNER
Single operator software and laser controller solution perfectly
matched and designed in unison to optimize laser processing
performance with advanced built-in application features toachieve…
• Precision, quality, and repeatability

Skywriting – delivers uniform laser density when processing
complex shapes and tight corners to avoid “burn marks” caused byover-processing.

• Throughput improvement• System failure detection• Process data archiving

Built-In ScanScript – single solution for multiple applications
includes unique application specific features including 3D model
design capabilities and file importing.

Extreme Processing Detail - Industry leading 24-bit resolution
controller combined with a precise, low-drift galvanometer set
enables greater processing detail for best-in-class sintered metal
structure and surface finish.

ScanPack Trajectory Planning – Fastest 3-axis scan head withadvanced software controls including patented technology that
optimizes the scan pattern to eliminate wasted galvanometer
movement.

Synchronization – high degree of stitching accuracy for multiscanning head systems.

Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

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5FIREFLY3D MULTI-HEAD CONFIGURATIONSCreating larger LPBF objects or laser processing larger areas canbe accomplished with FIREFLY3D and ScanMaster™ Controller/Designer. Multiple FIREFLY3D scan heads can be configured into a
multi-head system to expand the working field. The highly accurate
beam placement combined with a synchronization feature delivers
supreme stitching field accuracy, covering areas as large as 1800 x
1800 mm with an impressive laser spot size of 120 µm.

Quad Configuration

Edge Offsets

YX• Y: 34.2 mm• X: 55.0 mm

Dual Head Configuration

FIREFLY3D
Configuration

Working Distance(mm)Maximum
Field Size(mm)Laser Spot Size
(M2 = 1.1, µm)

SR Quad Head

200430 x 430

25

MR Quad Head450

860 x 860

46

MR Quad Head

650

1240 x 1240

63

LR Quad Head

650

1240 x 1240

63

LR Quad Head

1000

1840 x 1840

92

Dual In-Line Configuration

FIREFLY3D
Configuration

Working Distance(mm)

Maximum
Field Size(mm)Laser Spot Size
(M2 = 1.1, µm)

FIREFLY3D
Configuration

Working Distance(mm)Maximum
Field Size(mm)Laser Spot Size(M2 = 1.1, µm)

SR Dual Head200

215 x 430

25

SR Dual Head

200430 x 215

25

MR Dual Head

450

430 x 860

46

MR Dual Head450

860 x 430

46

MR Dual Head

650

620 x 1240

63

MR Dual Head

650

1240 x 620

63

LR Dual Head

650

620 x 1240

63

LR Dual Head

650

1240 x 620

63

LR Dual Head

1000

920 x 1840

92

LR Dual Head

1000

1840 x 920

92Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

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6FIREFLY3D SPECIFICATIONSSpecifications
OpticalWavelength1050 nm - 1090 nm

Laser Power

Maximum 1100 W

Input Clear Aperture

20 mm

Maximum Angular Velocity

50 rad/s

Integrated Pointer Laser Wavelength

633 nmRepeatability

1 µrad RMS

Offset Drift< 10 µrad

Tracking Delay

0.2 msCommand Resolution

24 bit for GSB

Step Response

10 mrad-opt step | 100 µsec

Maximum Acceleration

100,000 rad-opt/sec2

Automated Calibration Accuracy

5 µm

Process Monitoring
Low Monitoring Band

450 nm - 950 nm

High Monitoring Band

1200 nm - 2000 nm

Communications & Interfaces
Laser Power Monitoring

Power Monitoring Port | Optional: Power SensorProtocols

XY2-100 | XY2-100 (enhanced) | GSB

Process Monitoring Sensor Interface

High Speed Serial Output Analog Inputs

Analog Inputs

2 Analog Input Channels (0-10Vdc)

Diagnostics PortUSB or bridged access via SMC to allow access to servo driver function and status reporting

Cooling
Cooling Method

Water Cooled

Cooling Water Inlet Temperature

18°C ~ 20°C

Inlet Pressure

3 Bar - 4 Bar

Volume Flow

1.2 l/min - 2.2 l/min

Humidity (non-condensing)Maximum 80 %RH

Enclosure
IP Rating

IP65

Max Dry Weight

12 Kg

Dimensions (L x W x H)
Electrical Supply

Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

290 mm x 255 mm x 140 mm
48 Vdc +/- 2 Vdc

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7FIREFLY3D DIMENSIONS
Dimensions are in mm

Notes:All angles are in optical degrees, unless otherwise noted. Dimensions are in millimeters. All specifications are subject to change without notice.

CONTACT US
Americas, Asia Pacific

Europe, Middle East, Africa

China

Japan

Novanta Headquarters
Bedford, USA
P +1-781-266-5700

Novanta Europe GmbH
Wackersdorf, Germany
P +49 9431 7984‑0

Novanta Sales & Service OfficeShenzhen, China
P +86-755-8280-5395

Novanta Service & Sales Office
Tokyo, Japan
P +81-3-5753-2460

Photonics@Novanta.com

Milan, Italy
P +39-039-793-710

Suzhou, China
P +86-512-6283-7080

Photonics.Japan@Novanta.com

Photonics@Novanta.com
Photonics.China@Novanta.com

Copyright 2024 © Novanta Corporation. All rights reserved. Specifications subject to change without notice

www.NovantaPhotonics.com
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