Laser Based Fabrication of Freeform Optics

PowerPhotonic has pioneered an innovative laser micro-machining process to produce precision, free-form micro-optics. Our manufacturing technology, based on fundamental research carried out at Heriot-Watt University, enables us to rapidly iterate prototypes without setup costs at short turnaround times, and to cost-efficiently produce high-volume custom optics. The successful applicant will investigate new and improved methods of fabricating freeform micro-optics fabrication that will encompass: originating and investigating, new and improved methods of forming optical surfaces in a range of materials; coupling these forming methods to new and improved approaches in surface-finishing; and exploring new approaches to process metrology. The aim is to provide PowerPhotonic with the next generation of process technology based on fundamental research, and we expect this project to substantially further the company's capabilities - how to go deeper, steeper, with a faster process, improving device performance and quality. The project will cover technologies from Selective Laser Etching and Femto-second Laser Processing, to Laser Smoothing, and potentially Ultra Precision Machining. The investigator in this applied EngD will be a member of PowerPhotonic's R&D Technology Acquisition team, working onsite in Dalgety Bay (Fife), as well as at Heriot Watt University (Edinburgh) and potentially (and for very short periods) at third party locations (supported throughout by PowerPhotonic). During the project, the applicant will build a diverse skillset in the modelling, design, and the realisation of process technology. As such, they should have an enthusiasm for tackling challenging problems across a range of topics such as system design, laser-based materials processing, and optical surface metrology, as well as technologies associated with these topics.
The research direction we propose in the project abstract (reiterated above, [b]) will generate a novel forming-and-finishing process. We aim to be unique in the industry. Some of the forming technologies exist at very low TRL. They are solutions looking for problems, much like the invention of the laser itself. The finishing technology is little understood, and often crudely deployed, outside of PowerPhotonic. We have taken this embodiment of the process as far as we wish to, and require a next generation leap. Outside of this project (PowerPhotonic and Heriot-Watt) we're aware of nobody working in this area, and certainly nobody with the head start we possess.

Complementing our Pathways to Impact document, here we state the expected real-world impact, which is of course the leading priority for our industrial partners. Their confidence that the proposed CDT will deliver valuable scientific, engineering and commercial impact is emphasized by their overwhelming financial support (£4.38M from industry in the form of cash contributions, and further in-kind support of £5.56M).

Here we summarize what will be the impacts expected from the proposed CDT.

(1) Impact on People
(a) Students
The CDT will have its major impact on the students themselves, by providing them with new understanding, skills and abilities (technical, business, professional), and by enhancing their employability.
(b) The UK public
The engagement planned in the CDT will educate and inform the general public about the high quality science and engineering being pursued by researchers in the CDT, and will also contribute to raising the profile of this mode of doctoral training -- particularly important since the public have limited awareness of the mechanisms through which research scientists are trained.

(2) Impact on Knowledge
New scientific knowledge and engineering know-how will be generated by the CDT. Theses, conference / journal papers and patents will be published to disseminate this knowledge.

(3) Impact on UK industry and economy
UK companies will gain a competitive advantage by using know-how and new techniques generated by CDT researchers.
Companies will also gain from improved recruitment and retention of high quality staff.
Longer term economic impacts will be felt as increased turnover and profitability for companies, and perhaps other impacts such as the generation / segmentation of new markets, and companies receiving inward investment for new products.

(4) Impact on Society
Photonic imaging, sensing and related devices and analytical techniques underpin many of products and services that UK industry markets either to consumers or to other businesses. Reskilling of the workforce with an emphasis on promoting technical leadership is central to EPSRC's Productive Nation prosperity outcome, and our CDT will achieve exactly this through its development of future industrially engaged scientists, engineers and innovators. The impact that these individuals will have on society will be manifested through their contribution to the creation of new products and services that improve the quality of life in sectors like transport, dependable energy networks, security and communications.

Greater internationalisation of the cohort of CDT researchers is expected from some of the CDT activities (e.g. international summer schools), with the potential impact of greater collaboration in the future between the next generations of UK and international researchers.