Aerotech and Light Conversion Collaborate to Advance Precision

Aerotech Inc., a specialist in precision motion control and automation, has partnered with Light Conversion, a manufacturer of femtosecond lasers to establish an advanced research and development laboratory in Sunnyvale, Calif. The 43,000-sq.-ft. facility, operational since February 2025, is focused on advancing laser processing solutions for applications across semiconductor manufacturing, electronics and medical device fabrication.

The collaboration integrates Light Conversion’s Carbide 80W femtosecond laser with Aerotech’s custom laser scanning and motion control components. The system features an AGV-HPO high-dynamic laser scan head, designed to deliver high-speed acceleration and minimize trajectory errors during processing. The motion platform utilized Aerotech’s linear and rotary stages, which provide flexibility and accuracy for working with a range of part geometries such as round, tubular or flat substrates.

Key technical capabilities include Aerotech’s programming innovations such as Infinite Field of View (IFOV) and Position Synchronized Output (PSO), which enhance speed and precision to submicrometer levels without impacting throughput or quality. System control is centralized through a single Automation1 motion controller to streamline setup and operational efficiency.

The partnership leverages Light Conversion’s femtosecond laser technology and BiBurst pulse operation alongside Aerotech’s precision motion and scanner technology to explore novel laser micromachining processes. This enables targeted advancements in high-precision applications pertinent to semiconductor device manufacturing and medical technology sectors.

The Sunnyvale lab is equipped with diagnostic instruments such as microscopes to support detailed evaluation and development of laser processing techniques, including cutting, drilling, marking and material modifaction. The facility is designed to facilitate collaborative work with customers and partners addressing complex manufacturing challenges.

This technical collaboration aligns with ongoing industry efforts to push the boundaries or microfabrication precision and throughput by combing ultrafast technology with high-performance motion control systems.

After learning about the collaboration, Machine Design had some questions about practical engineering considerations behind integrating ultrafast laser sources with precision motion systems, so we reached out to Scott Schmidt, applications engineering group manager at Aerotech.

Editor’s Note: The following Q&A may have been edited for clarity, style and length.

Machine Design: What practical advantages or improvements have you observed when integrating femtosecond lasers with advanced motion control systems in microfabrication for semiconductor and medical device manufacturing?

Scott Schmidt: Femtosecond lasers allow for cleaner ablation and micromachining compared to pico- or nanosecond tools. This can allow finer features to be realized, which in turn means that better precision motion may be leveraged in these challenging applications.

MD: Can you describe the biggest engineering challenges when designing ultra-precise laser processing machines? How do technologies like Infinite Field of View (IFOV) and Position Synchronized Output (PSO) help address these challenges?

SS: Within the realm of ultra-precise laser processing systems, throughput is key. As many of these applications might originally have been implemented with fixed-beam processing in mind, either the underlying stage dynamics must be heavily optimized or the beam itself must be steered using high-speed galvanometers to decrease cycle times. Using galvos is really ideal for two key reasons.

MD: What role do high dynamic laser scan heads like the AGV-HPO play in balancing speed and precision in laser processing? How important is the integration of laser and motion control technologies to overall system performance?

SS: As noted above, if the motion controller is advanced enough (equipped with IFOV, for instance), then galvos provide the best of both worlds. Users can achieve tens or hundreds of G’s of effective spot acceleration on the machining plane while still maintaining single-digit micron dynamic errors. The motion controller must be able to seamlessly combine and synchronize the galvo and stage motion with essentially zero-latency laser firing, and PSO accounts for that.

MD: From your perspective, what emerging trends or technological breakthroughs could result from collaborations like Aerotech and Light Conversion, and how might these shape the future of laser-based manufacturing systems?

SS: End users benefit when cutting-edge laser technology is married with the best in motion control. With the ability to craft tailored femtosecond laser pulse regimes, users can machine materials in ways that were impossible just a few years ago. Combining that with the ability to place the laser energy with nanometer-level confidence enables fabrication of the next generation of electronic devices, including life-saving medical devices, portable electronics and more.

MD: What are the key considerations and best practices for machine designers and integrators when customizing and implementing complex laser scanning and motion control systems in diverse manufacturing environments?

SS: The fundamentals will always be important. It is essential to have well-designed, stiff machine frames combined with reliable laser sources and the highest precision motion platforms. But machine designers shouldn’t be afraid to expose the pain points of conventional machining systems. Both the motion and laser should be controlled seamlessly and synchronously within a single interface. As much of the laser setup and part articulation as possible should be automated.

The system should be robust and self-diagnosing to avoid downtime. Because the laser is akin to the machine’s engine and motion control is like its transmission, it’s natural to expect those most important subsystems to offer these types of capabilities. Furthermore, laser and motion suppliers should stand ready to proactively offer these features to the design community.