Automated assembly and alignment of NIR and MIR external cavity diode laser systems

Laser systems operating in the near-infrared (NIR) and mid-infrared (MIR) spectral regimes have become indispensable tools for a wide range of applications, including spectroscopy, metrology, and emerging quantum technologies. However, high manufacturing costs and variability due to manual assembly remain significant barriers to widespread adoption. This work introduces an automated assembly and alignment approach for NIR and MIR external cavity diode laser systems, leveraging robotic systems and artificial intelligence in the vision system for edge detection to enhance precision, reproducibility, and efficiency while significantly reducing production costs and time.

The automation process achieves positioning accuracy better than 100nm across all three translational degrees of freedom and angular accuracy exceeding 0.6 arcminutes. Continuous in-situ monitoring of optical and spectral performance during each alignment step ensures high reproducibility and optimal laser performance. A key focus of this approach is achieving symmetrical laser beams with well-defined divergence angles, which are crucial for effective cavity alignment. The method is demonstrated through the alignment of external cavity lasers with Volume-Bragg-Grating components, showcasing examples of NIR VBG lasers with varying cavity lengths.

This automated production concept represents a significant advancement in industrial laser manufacturing by addressing challenges associated with manual processes, such as variability and inefficiency. It provides a scalable solution for producing high-performance laser systems at reduced costs while maintaining stringent quality standards.