Manufacturing and reliability analysis of high brightness blue light semiconductor laser

The blue semiconductor laser with a wavelength range of 450nm has developed rapidly in recent years. For high-reflective and high-thermal conductive materials represented by copper, gold and high-strength aluminum, the absorption rate of blue laser is 5-10 times than infrared lasers. Blue laser can achieve high-quality and consistent welding results, stable melt pools and no spatter. With the development of blue semiconductor laser technology, there is a growing demand for higher brightness and reliability. Based on the practical application background, we have designed and implemented a stable high-brightness blue laser. Through BPP theory and ZEMAX simulation calculation, 48pcs TO-packaged 5.5W blue lasers are coupled into a 105μm core diameter 0.22NA fiber using polarization and optical fiber coupling technology. More than 250W output power is obtained with coupling efficiency exceeds 90% and electro-optical efficiency exceeds 35%. The high brightness blue laser has passed various reliability tests including accelerated aging for 7000 hours, 85°C high temperature storage, -40°C low temperature storage, -20°C to approximately 70°C temperature cycling test, vibration and mechanical shock test. The stable high-brightness blue laser finds significant applications in medical, 3D printing and welding.