SquareLaser beam

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A: A flat top beam shaper can create round, square, rectangle and line shapes. Holo/Or’s diffractive shapers are not limited by these shapes, and can create any arbitrary distribution, such as several rectangles or even letters.

Flat laser

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The second type of flat top beam shapers is flat top diffusers. These elements work by overlaying the beam over itself multiple times, creating a mixed beam with a Flat Top envelope. They are more suitable for multimode, less coherent lasers, where this overlaying does not generate strong speckling. Their sharpness tends to be lower than Analytical shapers, but they are significantly less sensitive to system tolerances and not sensitive to input beam parameters. In this article we focus on the Analytical Top Hat shapers, as the Diffusers are extensively discussed in a separate article.

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flat-topbeamshaper thorlabs

Holo/Or has an extensive installation guide and application notes, aimed at facilitating diffractive Top Hat use. All analytical Top Hat types are sensitive to tolerances, and require careful work and pre-alignment.  The main requirements to use Top Hat shapers are:

A: A beam shaper in an optical component that turns an input laser beam into a flat angular distribution with a pre-defined shape. i.e a beam where the intensity is the same everywhere inside the shape.

A: flat top laser beam shapers are used in a variety of laser applications, mostly in laser material processing. These include micromachining, drilling, cutting, scribing, surface treatments and others.

Flat beam laserpointer

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FlattopbeamShaper

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A magnifying glass lens is a convex lens that is used to produce a magnified image of an object. The lens is usually mounted in a frame with a handle.

Flat-top Gaussian

Top-Hatbeamshaper

Top Hat shapers are either refractive or diffractive optics. Refractive beam shapers are based on high accuracy freeform surfaces that refract the incoming laser beam to create the desired flat top intensity profile. Diffractive beam shapers are windows patterned by a diffractive pattern that, for the design wavelength, creates the requires free-form phase to shape the laser into a Top Hat at the far-field (or lens focal plane) .

A: Diffractive Top Hat shapers offer absolute angular accuracy, enabling shaping to dimensions of a few times the diffraction limited spot size. Such small shapes are highly useful in micro- machining and other precise laser material processing

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A: For Single mode, coherent laser shaping, analytical beam shapers are optimal- either diffractive or refractive. For less coherent lasers, flat top diffusers are optimal.

Diodelaser beamshape

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Most Laser beams have a Gaussian profile, i.e. they have higher energy in the center, with a slow decay with increasing radius. This behavior is often sub-optimal, for example if the laser beam is used for a process with a certain energy threshold; a lot of energy is wasted by being either unnecessarily above or below this value.  This issue can be solved by using flat top beam shapers, also called top hat beam shapers. Flat top beam shapers are optical elements that convert an incoming laser beam with a given intensity profile into a flat top beam profile, i.e. a profile where the energy is spread equally over the beam profile.

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There are in general two types of Flat Top shapers, and the choice between them be made based on the temporal coherence level of the laser.   Analytical Top Hat beam shapers are suitable for coherent, single mode input, and are usually designed for a TEM00 Gaussian input beam with M2<1.3 . They work by a continuous transformation of the phase front, without mixing or overlaying any section of the beam, thus they create a smooth, speckle-less Flat-Top intensity profile, with very high conversion efficiency. To achieve optimal shaping, these Top Hat shapers require a well-defined input beam diameter, good centering accuracy and laser-grade, aberration free focusing and relay optics with a clear aperture of at least X2 input beam diameter.