Aerotech unveils high-performance successor for the cylindrical laser processing of medical devices

The LaserTurn280 is based on Aerotech's tried-and-tested PRO280LM linear stage design. The system is available in three versions with the ASR1400, ASR1100 and ACS150 rotary stage drives. Depending on the configuration, tube diameters ranging from 0.3 to 30 mm can be machined. A range of clamping systems is available, including collets (TF20, W12) with so-called 'dead length' and ER precision collets (ER16, ER25, ER40). The linear travel is 300 mm, and the maximum travel speed is 1,000 mm/s.

Collet chucks with 'dead length' minimise axial movement of the tube and reduce the risk of stitching errors during feed. This is particularly important when machining longer workpieces such as hypotubes. The clamping mechanism is pneumatically actuated and is designed for operation with dry, oil-free nitrogen or compressed air.

"The LaserTurn280 is the result of direct feedback from the market," explains Brian Fink, Product Manager at Aerotech. "Our customers need platforms that can be quickly integrated into their existing production lines whilst enabling higher throughput. The LaserTurn280 was developed precisely to meet these requirements."

High accuracy in linear and rotary movements

According to the manufacturer, the achievable calibrated accuracy is +/-1 um (linear) and +/-30 urad (rotary), with bidirectional repeatability of +/-0.4 um and +/-15 urad respectively. The system is driven by ironless linear motors with non-contact optical encoders. The design is engineered for high rigidity and protects internal components from contamination. This is particularly relevant for wet cutting applications. The LaserTurn280 can be supplied in either a dry or wet cutting configuration; the latter features an integrated fluid handling system.

To simplify integration, the platform features an integrated cable management system and a clear aperture for tube passage. Optional pneumatic grippers at the front and rear enable automated workpiece handling. Mounting is via eight M8 fixing points.

"We have designed the platform specifically to meet the requirements of medical technology manufacturing," explains Brian Fink. "This means minimal tube scrap, reproducible part quality and an architecture that allows machine builders to move quickly into series production."

Designed for the Automation1 controller

The tube laser system is designed for use with Aerotech's Automation1 motion controller. Among other features, this supports the Position Synchronised Output (PSO) function for precise synchronisation of the laser pulse and axis movement. In addition, Enhanced Tracking Control (ETC) is available - a function that reduces path errors during the machining of fast and complex contours. Both technologies are particularly relevant for stent manufacturing, where tight geometric tolerances and short cycle times are equally essential.

Laser-cut, cylindrical medical devices are used, amongst other things, in coronary and neurovascular stents, structural heart components, peripheral vascular implants and instruments for minimally invasive procedures. Workpieces range from a few millimetres to lengths of over one metre. With its selection of rotary stage drives and collet options, the LaserTurn280 is designed for a wide range of these applications.

"The demands of medical device manufacturing are increasing: smaller structures, tighter tolerances and higher production volumes," confirms Brian Fink. "The LaserTurn280 supports this development and enables integration without the need for complex adjustments to individual components."