# US 8,570,657 B2 · Fast-axis collimator array > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,570,657 B2 - Document ID: US8570657B2 - Status: Granted - Kind: B2 - Application number: 13/291,974 - Filed: 2011-11-08 - Published: 2012-06-07 - Granted: 2013-10-29 - Earliest claimed: 2010-11-09 - Assignees: Power Photonic Ltd. - Applicants: Roy McBride; Matthew Oren Currie; Jozef Jacek Wendland - Inventors: Roy McBride; Matthew Oren Currie; Jozef Jacek Wendland - Web page: https://patentgrep.com/patent/US8570657B2 ## CPC - G02B 19/0057: {in the form of a laser diode array, e.g. laser diode bar (semiconductor laser arrays with beam combining arrangement H01S5/4012)} - B29D 11/00298: {Producing lens arrays} - B29D 11/00951: {Measuring, controlling or regulating} - G02B 19/0014: {at least one surface having optical power} - G02B 19/009: {for use with infrared radiation} - G02B 27/0961: {Lens arrays (lens arrays per se G02B3/0006)} - G02B 27/0966: {Cylindrical lenses (cylindrical lenses per se G02B3/06)} - G02B 27/30: Collimators - H01S 5/005: {Optical components external to the laser cavity, specially adapted therefor, e.g. for homogenisation or merging of the beams or for manipulating laser pulses, e.g. pulse shaping (H01S5/026, H01S5/18388 take precedence)} - H01S 5/405: {Two-dimensional arrays} - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - H01S: DEVICES USING THE PROCESS OF LIGHT AMPLIFICATION BY STIMULATED EMISSION OF RADIATION [LASER] TO AMPLIFY OR GENERATE LIGHT; DEVICES USING STIMULATED EMISSION OF ELECTROMAGNETIC RADIATION IN WAVE RANGES OTHER THAN OPTICAL ## Abstract A micro-optical element for use with an edge-emitting laser diode bar stack, the element comprising a plurality of spaced apart fast-axis collimators formed as a monolithic array, wherein the spacing between the collimators in the fast-axis varies across the micro-optic element. A method of manufacturing a micro-optical element for use with a laser diode bar stack, using a wavelength stabilized CO2 laser is also described. ## Claims ### Claim 1 A micro-optical element for use with an edge-emitting laser diode bar stack, the element comprising a plurality of spaced apart fast-axis collimators formed as a monolithic array, wherein the plurality of fast-axis collimators each have characteristics determined by emitter locations in the measured laser diode bar stack and the spacing between the collimators in the fast-axis varies across the micro-optic element. ### Claim 2 (depends on 1) A micro-optical element according to claim 1 wherein the array is two-dimensional. ### Claim 3 (depends on 1) A micro-optical element according to claim 1 wherein the array is one-dimensional. ### Claim 4 (depends on 1) A micro-optical element according to claim 1 wherein each fast-axis collimator comprises a lens form in the element. ### Claim 5 (depends on 4) A micro-optical element according to claim 4 wherein each lens form describes a lens shape. ### Claim 6 (depends on 5) A micro-optical element according to claim 5 wherein a depth of the lens shape is in the range 50 μm to 500 μm. ### Claim 7 (depends on 6) A micro-optical element according to claim 6 wherein a surface of the element is smoothed and polished. ### Claim 8 (depends on 4) A micro-optical element according to claim 4 wherein each lens form matches an emitter in a laser diode bar stack. ### Claim 9 (depends on 4) A micro-optical element according to claim 4 wherein the lens shape is interpolated along the slow-axis to give a continuous transition between lens forms. ### Claim 10 (depends on 1) A micro-optical element according to claim 1 wherein the element includes optical characteristics of bow-tie correction. ### Claim 11 (depends on 1) A micro-optical element according to claim 1 wherein the element includes optical characteristics of slow-axis collimation. ### Claim 12 (depends on 1) A micro-optical element according to claim 1 wherein each collimator on the fast-axis is modified to one producing a predetermined function in the far-field of each emitter. ### Claim 13 (depends on 12) A micro-optical element according to claim 12 wherein each collimator on the fast-axis is modified to one producing a fast-axis flat-top function in the far-field of each emitter. ### Claim 14 (depends on 1) A micro-optical element according to claim 1 wherein the monolithic element is made of fused silica. ### Claim 15 A method of manufacturing a micro-optical element for use with a laser diode bar stack, comprising the steps: (a) providing a wavelength stabilized CO2 laser with stable laser power operating on a laser line selected from the CO2 spectrum; (b) providing a computer controlled acousto-optic modulator to give temporal control on laser pulses from the CO2 laser; (c) providing a computer controlled X-Y translation stage; (d) locating a monolithic substrate on the translation stage; and (e) operating the laser, acousto-optic modulator and the translation stage to ablate portions of the substrate in a shot-by-shot raster scan regime and form an array of predetermined lens forms on the substrate. ### Claim 16 (depends on 15) A method of manufacturing a micro-optical element according to claim 15 wherein the substrate is fused silica. ### Claim 17 (depends on 15) A method of manufacturing a micro-optical element according to claim 15 wherein the method includes the additional step of operating the laser, acousto-optic modulator and the translation stage to melt the silica in a continuous wave (CW) scan regime to laser micro-polish the surface of the micro-optical element. ### Claim 18 (depends on 15) A method of manufacturing a micro-optical element according to claim 15 wherein the method includes the additional step of operating the laser, acousto-optic modulator and the translation stage to melt the silica in a shot-by-shot raster scan regime to laser micro-polish the surface of the micro-optical element. ### Claim 19 (depends on 15) A method of manufacturing a micro-optical element according to claim 15 wherein the method includes the step of analysing the emitter geometries of the laser diode bar stack to determine shapes for the lens forms required.