Frequency-comb enabled metrology for manufacturing
Lead Research Organisation:
Heriot-Watt University
Department Name: Sch of Engineering and Physical Science
Abstract
This proposal aims to transition today's highest precision laser technology -- optical frequency combs -- from the lab to the factory, establishing the technique of dual-comb distance metrology as an enabling technology for manufacturing the next generation of precision-engineered products, whose functionality relies on micro-/ nanoscale accuracy.
Optical techniques form the basis of critical industrial distance metrology, but face compromises between accuracy, precision and dynamic range. Time-of-flight methods give mm accuracy over an extended range, while interferometric trackers achieve nm precision but with no absolute positional accuracy. By developing novel dual-comb metrology techniques, this project will bridge the gap between precision and extended-range accuracy, providing traceable nm precision, with almost unlimited extended-range operation. For manufacturing industry, comb metrology therefore addresses the important problem of how to verifiably fabricate macro-scale objects with nano-/micro-precision.
Building on Heriot-Watt's frequency-comb expertise, we will develop Ti:sapphire and Er:fibre dual combs, with the aim of demonstrating nm-precision controlled-environment metrology using Ti:sapphire, and micron-precision free-space ranging using eye-safe Er:fibre. Besides their novel applications in precision metrology, by implementing new efficient and compact diode-pumping schemes our research will extend laser comb technology in a way that makes these systems suitable for deployment in a wide range of environments outside the research lab, for example as modules in a precision quantum navigation system.
Our project integrates key academic and industrial partners who will contribute resources and expertise in lasers (Chromacity), precision micro-optics (Powerphotonic), industrial metrology and manufacturing (Renishaw), ultra-precision metrology (EPSRC Centre for Innovative Manufacturing in Ultra Precision and CDT in Ultra Precision) and applications in large optics for astronomy (STFC UK Astronomy Technology Centre). The commitment of our partners is evidenced by >£300K of support, including £145K of cash which will be used primarily to support two EPSRC EngD and PhD students recruited to the project.
The project aligns closely with the EPSRC's Manufacturing the Future challenge theme and the ICT Photonics for Future Systems priority, as well as the EPSRC's training agenda, by engaging EngD and PhD researchers from the CDT in Applied Photonics and the CDT in Ultra Precision. More generally, the project will support the UK's high-precision manufacturing and metrology communities, with potential academic and industrial benefits.
By the end of the project we expect to have demonstrated and evaluated dual-comb distance metrology in a variety of practical manufacturing contexts (machine calibration, in-process control, finished-product inspection), and to be in a position to translate the technology into our industrial and academic partners.
Optical techniques form the basis of critical industrial distance metrology, but face compromises between accuracy, precision and dynamic range. Time-of-flight methods give mm accuracy over an extended range, while interferometric trackers achieve nm precision but with no absolute positional accuracy. By developing novel dual-comb metrology techniques, this project will bridge the gap between precision and extended-range accuracy, providing traceable nm precision, with almost unlimited extended-range operation. For manufacturing industry, comb metrology therefore addresses the important problem of how to verifiably fabricate macro-scale objects with nano-/micro-precision.
Building on Heriot-Watt's frequency-comb expertise, we will develop Ti:sapphire and Er:fibre dual combs, with the aim of demonstrating nm-precision controlled-environment metrology using Ti:sapphire, and micron-precision free-space ranging using eye-safe Er:fibre. Besides their novel applications in precision metrology, by implementing new efficient and compact diode-pumping schemes our research will extend laser comb technology in a way that makes these systems suitable for deployment in a wide range of environments outside the research lab, for example as modules in a precision quantum navigation system.
Our project integrates key academic and industrial partners who will contribute resources and expertise in lasers (Chromacity), precision micro-optics (Powerphotonic), industrial metrology and manufacturing (Renishaw), ultra-precision metrology (EPSRC Centre for Innovative Manufacturing in Ultra Precision and CDT in Ultra Precision) and applications in large optics for astronomy (STFC UK Astronomy Technology Centre). The commitment of our partners is evidenced by >£300K of support, including £145K of cash which will be used primarily to support two EPSRC EngD and PhD students recruited to the project.
The project aligns closely with the EPSRC's Manufacturing the Future challenge theme and the ICT Photonics for Future Systems priority, as well as the EPSRC's training agenda, by engaging EngD and PhD researchers from the CDT in Applied Photonics and the CDT in Ultra Precision. More generally, the project will support the UK's high-precision manufacturing and metrology communities, with potential academic and industrial benefits.
By the end of the project we expect to have demonstrated and evaluated dual-comb distance metrology in a variety of practical manufacturing contexts (machine calibration, in-process control, finished-product inspection), and to be in a position to translate the technology into our industrial and academic partners.
Planned Impact
Our research programme will produce immediate academic impacts, with industrial, economic and societal impacts emerging over a longer timescale.
1. Impacts on Industry
More broadly, we expect the research to deliver sustained impact in the form of new metrology paradigms taken up by industrial early adopters to solve acute problems in precision manufacturing.
As an innovative new methodology, dual-comb distance metrology has considerable potential to address measurement problems across a variety of sectors and disciplines, for example: (i) in manufacturing, where the automotive, defence and aerospace sectors have fine tolerances for large critical parts, benefiting from machine-tools which are indexed using a laser comb; (ii) in the energy sector, where large turbine blades must be accurately profiled to verify they have been manufactured correctly, benefiting from the extended-range metrology aspects of our proposed research; (iii) the environmental protection sector, in which a range-gated spectroscopic approach, as is possible using dual-comb spectroscopy, will provide multi-species chemical monitoring.
Our named industrial partners will benefit from the project outcomes in different ways. By licensing intellectual property generated at HWU, each of our partners stands to benefit commercially: Renishaw, via access to a disruptive metrology technique not available to its competitors; Chromacity, by licensing laser technology which would open up new markets in metrology and sensing; and Powerphotonic, for whom micro-optical beam shaping of single emitters may become a significant area of growth driven by DPSS laser replacements and diode-laser projection systems.
More broadly, the development of a UK capability in dual-comb precision metrology for manufacturing from a small initial group of industrial stakeholders could lead to wider industrial adoption of the technique, with longer term commercial benefits to UK manufacturers from this emerging technology (see Case for Support, Section 3.4).
2. Impacts on Project Researchers
Through the training and personal development of two CDT students (one EngD and one PhD), the project will support UK industry's requirement for highly skilled researchers in applied photonics. The named Researcher Co-investigator, Dr. Zhaowei Zhang, will also be developed in his project management skills through mentorship with Reid and Faccio, his professional network with industry and access to formal staff development courses relevant to his personal development needs.
3. Impacts on Academic Researchers
We expect to generate new scientific and engineering knowledge in the separate areas of laser comb technology and applied precision metrology. Through the dissemination of our work in appropriate technical journals and conferences our results will influence the practice of other researchers in areas including laser development, frequency comb techniques, applied metrology and manufacturing research.
4. Socio-Economic Impacts
The precision and absolute accuracy provided by dual-comb metrology makes it realistic to expect the technique will have a positive societal and environmental impact by reducing waste and improving yields / productivity in manufacturing processes.
Our public engagement plan (see Pathways to Impact) includes activities which will reach the general public, increasing public awareness of the role of photonics and the value of precision manufacturing to the UK.
1. Impacts on Industry
More broadly, we expect the research to deliver sustained impact in the form of new metrology paradigms taken up by industrial early adopters to solve acute problems in precision manufacturing.
As an innovative new methodology, dual-comb distance metrology has considerable potential to address measurement problems across a variety of sectors and disciplines, for example: (i) in manufacturing, where the automotive, defence and aerospace sectors have fine tolerances for large critical parts, benefiting from machine-tools which are indexed using a laser comb; (ii) in the energy sector, where large turbine blades must be accurately profiled to verify they have been manufactured correctly, benefiting from the extended-range metrology aspects of our proposed research; (iii) the environmental protection sector, in which a range-gated spectroscopic approach, as is possible using dual-comb spectroscopy, will provide multi-species chemical monitoring.
Our named industrial partners will benefit from the project outcomes in different ways. By licensing intellectual property generated at HWU, each of our partners stands to benefit commercially: Renishaw, via access to a disruptive metrology technique not available to its competitors; Chromacity, by licensing laser technology which would open up new markets in metrology and sensing; and Powerphotonic, for whom micro-optical beam shaping of single emitters may become a significant area of growth driven by DPSS laser replacements and diode-laser projection systems.
More broadly, the development of a UK capability in dual-comb precision metrology for manufacturing from a small initial group of industrial stakeholders could lead to wider industrial adoption of the technique, with longer term commercial benefits to UK manufacturers from this emerging technology (see Case for Support, Section 3.4).
2. Impacts on Project Researchers
Through the training and personal development of two CDT students (one EngD and one PhD), the project will support UK industry's requirement for highly skilled researchers in applied photonics. The named Researcher Co-investigator, Dr. Zhaowei Zhang, will also be developed in his project management skills through mentorship with Reid and Faccio, his professional network with industry and access to formal staff development courses relevant to his personal development needs.
3. Impacts on Academic Researchers
We expect to generate new scientific and engineering knowledge in the separate areas of laser comb technology and applied precision metrology. Through the dissemination of our work in appropriate technical journals and conferences our results will influence the practice of other researchers in areas including laser development, frequency comb techniques, applied metrology and manufacturing research.
4. Socio-Economic Impacts
The precision and absolute accuracy provided by dual-comb metrology makes it realistic to expect the technique will have a positive societal and environmental impact by reducing waste and improving yields / productivity in manufacturing processes.
Our public engagement plan (see Pathways to Impact) includes activities which will reach the general public, increasing public awareness of the role of photonics and the value of precision manufacturing to the UK.
Organisations
- Heriot-Watt University (Lead Research Organisation)
- Chromacity Ltd (Collaboration)
- Renishaw (United Kingdom) (Collaboration, Project Partner)
- UNIVERSITY OF CAMBRIDGE (Collaboration)
- CRANFIELD UNIVERSITY (Collaboration)
- Atomic Weapons Establishment (Collaboration)
- PowerPhotonic (Collaboration)
- UK Astronomy Technology Centre (ATC) (Collaboration)
- Chromacity (United Kingdom) (Project Partner)
- UK Astronomy Technology Centre (Project Partner)
- University of Cambridge (Project Partner)
- PowerPhotonic (United Kingdom) (Project Partner)
- CRANFIELD UNIVERSITY (Project Partner)
Publications
Wright H.
(2021)
Carrier-free dual-comb distance metrology using two-photon detection
in Optics InfoBase Conference Papers
Wright H.
(2021)
Carrier-Free Dual-Comb Distance Metrology Using Two-Photon Detection
in 2021 Conference on Lasers and Electro-Optics, CLEO 2021 - Proceedings
Wright H.
Carrier-free dual-comb distance metrology using two-photon detection
in Optics InfoBase Conference Papers
Castro-Marin P
(2019)
Characterization of a carrier-envelope-offset-stabilized blue- and green-diode-pumped Ti:sapphire frequency comb.
in Optics letters
Mitchell T
(2021)
Dynamic measurements at up to 130-kHz sampling rates using Ti:sapphire dual-comb distance metrology
in Optics Express
Mitchell T
(2021)
Investigation of a diode-pumped Ti:sapphire laser modelocked using carbon nanotubes
in OSA Continuum
Wright H
(2023)
Multi-target two-photon dual-comb LiDAR.
in Optics express
Wright H.
(2022)
Two-Photon Dual-Comb LiDAR
in Optics InfoBase Conference Papers
Wright H
(2021)
Two-Photon Dual-Comb LiDAR
Title | DCR.mp4 |
Description | Two-second audio clip of the displacement of the loudspeaker-mounted mirror measured using the dual-comb ranging system. |
Type Of Art | Film/Video/Animation |
Year Produced | 2021 |
URL | https://opticapublishing.figshare.com/articles/media/DCR_mp4/16886533 |
Title | Original.mp4 |
Description | Two-second audio clip of the original audio waveform used to drive the loudspeaker-mounted mirror. |
Type Of Art | Film/Video/Animation |
Year Produced | 2021 |
URL | https://opticapublishing.figshare.com/articles/media/Original_mp4/16886536 |
Title | Original.mp4 |
Description | Two-second audio clip of the original audio waveform used to drive the loudspeaker-mounted mirror. |
Type Of Art | Film/Video/Animation |
Year Produced | 2021 |
URL | https://opticapublishing.figshare.com/articles/media/Original_mp4/16886536/1 |
Description | We continue to develop the Ti:sapphire and Er:fibre laser systems. A new form of Er:fibre laser has been developed for the project which offers much greater stability and is now being applied to dual-comb measurement. Phase control of the Ti:sapphire laser is under development, again aiming at a simple but very stable solution for precision metrology. Recent work has delivered on the aims of the project. We have succeeded in demonstrating high speed dual comb metrology using a Ti:sapphire comb system, and in proving simple reliable dual comb metrology with an Er:fibre system which has led to a project and patent application with Renishaw PLC. |
Exploitation Route | We expect to translate our lasers into an applicaiton with Renishaw PLC for manufacturing metrology. |
Sectors | Aerospace Defence and Marine Electronics Manufacturing including Industrial Biotechology |
URL | http://ultrafast.hw.ac.uk |
Description | Development has taken place of a fibre laser system and a concept for simple distance metrology using this. A patent application has been filed in Dec 2020, led by industrial sponsor Renishaw, based on the concept from Derryck Reid and Hollie Wright (both HWU). Work carried out in this EPSRC project has led to 5 years of funding by Renishaw and the Royal Academy of Engineering in 2023 as a 5-year Royal Academy of Engineering Research Chair award to Prof. Derryck Reid. We are now (2022+) working with Renisahw to bring the technology to market. |
First Year Of Impact | 2021 |
Sector | Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology |
Impact Types | Economic |
Description | Real-Time Dual-Comb LiDAR for Manufacturing |
Amount | £225,000 (GBP) |
Funding ID | RCSRF2223-1678 |
Organisation | Royal Academy of Engineering |
Sector | Charity/Non Profit |
Country | United Kingdom |
Start | 03/2023 |
End | 03/2028 |
Description | AWE plc |
Organisation | Atomic Weapons Establishment |
Country | United Kingdom |
Sector | Private |
PI Contribution | The Heriot-Watt team is working with AWE plc to apply dual-comb LiDAR to problems of interest to them. |
Collaborator Contribution | AWE have supported an EPSRC ICASE studentship in an area relevant to continuing research in two-photon dual-comb LiDAR. |
Impact | AWE support of PhD student Alexander Nelmes has led to papers listed in the outcomes for the project. Alexander is a named author on the relevant papers. |
Start Year | 2022 |
Description | Collaboration with Renishaw PLC |
Organisation | Renishaw PLC |
Country | United Kingdom |
Sector | Private |
PI Contribution | Co-creation of a frequency comb metrology system for industry. |
Collaborator Contribution | Cash contribution to support an EngD student working on the project. Co-creation of a frequency comb metrology system for industry. |
Impact | Patent applicaiton filed in late 2020. |
Start Year | 2014 |
Description | Frequency Combs for Manufacturing |
Organisation | Chromacity Ltd |
Country | United Kingdom |
Sector | Private |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Description | Frequency Combs for Manufacturing |
Organisation | Cranfield University |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Description | Frequency Combs for Manufacturing |
Organisation | PowerPhotonic |
Country | United Kingdom |
Sector | Private |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Description | Frequency Combs for Manufacturing |
Organisation | Renishaw PLC |
Country | United Kingdom |
Sector | Private |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Description | Frequency Combs for Manufacturing |
Organisation | UK Astronomy Technology Centre (ATC) |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Description | Frequency Combs for Manufacturing |
Organisation | University of Cambridge |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Heriot-Watt is the project lead. Our aim is to develop a new laser technology -- laser frequency combs -- of direct benefit to manufacturing metrology. |
Collaborator Contribution | Our partners are assisting in the development of the laser technology (PowerPhotonic, Chromacity) and the evaluation and optimisation of this in maufacturing metrology context (Cambridge, Cranfield, Renishaw, UKATC). Renishaw has supported a CASE student on this project and Cambridge a CDT student. |
Impact | Project is 1 year old so outcomes are still under development. |
Start Year | 2015 |
Title | APPARATUS AND METHOD FOR DISTANCE METROLOGY |
Description | APPARATUS AND METHOD FOR DISTANCE METROLOGY |
IP Reference | 2019025.2 |
Protection | Patent application published |
Year Protection Granted | |
Licensed | Yes |
Impact | Follow on funding from Renishaw PLC to HWU. |
Title | APPARATUS AND METHOD FOR DUAL-COMB DISTANCE METROLOGY USING MULTI-PHOTON DETECTION |
Description | An optical distance measurement or ranging apparatus is described. The apparatus includes at least one optical pulse generator (30,32; 80,94; 120,122; 180,202; 300,320) for generating a train of gating pulses and a train of probe pulses, the train of gating pulses having a different repetition rate than the train of probe 10 pulses. The gating and probe pulses may be ultrashort laser pulses generated by different free-running, mode-locked lasers. An optical probing arrangement is also provided for directing the train of probe pulses to one or more objects (42,44; 84,86; 188, 190; 232,234,236; 306,310) and for collecting returned probe pulses returned from the one or more objects. The objects may include a target object and a reference object. The apparatus comprises a multi-photon effect detector (58; 104; 140; 210; 324, 330) and is configured to direct both the train of gating pulses and the returned probe pulses to the multi-photon effect detector. The apparatus may be used for industrial inspection, machine calibration, position measurement or the like. |
IP Reference | WO2022118014 |
Protection | Patent / Patent application |
Year Protection Granted | 2022 |
Licensed | Commercial In Confidence |
Impact | Development of commercialisation of technique by Renishaw plc |
Description | Webinar |
Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | Webinars: H. Wright, "How Will the Latest Research Improve LiDAR's Application Potential," Laser Focus World webinar, online, 22nd June 2023. H. Wright, "Next Generation LiDAR for High-Priority Industrial Metrology Applications," Optica Lasers in Manufacturing Technical Group webinar, online, 29th August 2023. H. Wright, "Dual-Comb Ranging for Industrial Applications," Photonics Spectra webinar, online, 13th February 2024. |
Year(s) Of Engagement Activity | 2023,2024 |