Ultimate manufacturing performance is rarely determined by a single technology in isolation, but by the interaction and synergy between the comprising subsystems. This became the guiding principle behind the development of NEVIS, adopting the proven engineering concept of marginal gains.
Kristen Rivett, Business Development Executive at Watt Laser, explains the developmental process.
“We began with the motion system. Shifting away from the traditional gantry configuration, we upgraded to a split-axis mechanical design. By driving the workpiece along the Y-axis and moving the laser independently along the X-axis, we isolated the moving masses. This gained us smoother motion and transitions alongside higher speeds and acceleration.
“Achieving this new level of motion control naturally forced a new question: how could we best optimise the laser beam? We modified the focusing optics within the laser head to achieve a smaller, more precise beam diameter. This gained us higher energy density which meant we were able to reduce the laser power, highlighting a massive industry misconception that more power is better.
“Once we perfected the beam, we turned our attention to laser energy delivery. Through recipe tuning and optimisation, we developed our motion system to manage laser energy dynamically, a process we call Energy Position Optimisation (EPO). By synchronising motion control and laser output in real-time, the laser places energy exactly where and when it’s needed. This provides dynamic scaling and adaptation to real-time motion conditions, including velocity changes, acceleration, deceleration and varying feature sizes or geometries. This allows us to cut cleanly with no worry of distortion, burning or edge degradation.
“To complement our motion improvements, we next focused on gas flow and turbulence control. We optimised the cutting head design to create a larger reservoir within the cutting head, ensuring a more consistent gas supply during processing. A dual-entry gas inlet further increased flow capacity and improved pressure stability, allowing for a more controlled cutting environment.
“Next, the nozzle underwent an iterative design process, drawing on both lessons learned across the industry and incorporating features such as curved and chamfered edges for smooth movement across the workpiece. Our goal was to maximise the Bernoulli effect, helping to maintain the workpiece at the optimal laser focal plane throughout the cutting process. This was then tested and adjusted iteratively for the best overall performance.
“Of course, mechanical performance is only one part of the equation. Even the most advanced hardware cannot achieve consistent results if the process depends too heavily on manual setup and operator judgement. Small differences in setup, parameter selection and day-to-day operation can all introduce variation. To make the optimised laser cutting process truly repeatable and reproducible, we needed to remove as much opportunity for variation as possible. This is why we anchored NEVIS to the Watt Laser Software Suite. Designed with a simple ‘follow the green button’ philosophy, our software guides operators through setup, daily operation and maintenance in a logical sequence, removing as much need for human intervention and guesswork as possible. Operators don’t need to think about the next step, it’s right in front of them. This made it the perfect final piece of the NEVIS lineup.
“Under the strategy of marginal gains, our ultimate advantage was bringing fresh, young minds together to challenge legacy thinking. The industry achieved great things with the technology available at the time. But now, it is time for a new generation to make the most of what is possible with the technology available today. NEVIS sets a new industry benchmark for SMT fusion laser cutting. From this point forward, the standard has changed, and the rest of the industry must keep pace.”
Contact: Kristen Rivett