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DE3D Gaussian Focal Shaper
An all-reflective optic that reshapes the focus of a standard Gaussian beam, from a sharp, tapered peak into an elongated column of near-constant intensity, up to 5× the depth of focus. The process stops depending on a knife-edge focus. Height tolerances, part warpage and thermal lensing no longer throw the result off: processing runs faster, rejects fall and quality stays consistent even in demanding, high-power environments.
A focus that survives real parts and real power
In industrial laser processing, focus position is critical, and a standard Gaussian beam has almost none to spare. Height tolerances, warped or tilted parts, and thermal lensing at power all push the workpiece out of the narrow focal region, and quality drifts. The Focal Shaper elongates the focus and homogenizes its width, holding a usable spot across a far longer stretch of the beam axis. The process becomes tolerant instead of fragile: it keeps running through the height variation of a real part, and it holds up in multi-kW setups where transmissive optics would drift.
Built for robust industrial processing
Extended depth of focus
Up to 5× the depth of focus of a standard Gaussian beam: the focus is stretched along the propagation axis, so the process window is dramatically wider and far more tolerant of defocus.
Homogenized focus width
A reliable, consistent energy distribution across the elongated focus. The spot stays usable through depth instead of collapsing to a single sharp waist.
Thermal-lensing resistant
All-reflective, micro-structured mirror optics stay stable at power, ideal for multi-kW setups where transmissive optics drift under thermal load.
Focus elongation and beam width are individualized to your laser and process as standard.
The same beam, held usable across a longer focus
Simulation of a standard Gaussian focus beside the shaped focus. The beam diameter stays near its minimum over a far longer stretch of the z-axis, and the on-axis intensity flattens into a plateau instead of a single sharp peak: a longer, more uniform working region.
Simulated for λ = 1070 nm, M² = 1.4, f = 255 mm, beam Ø = 12 mm (1/e²). Values are configuration-specific and confirmed per setup.
2× focal elongation, in numbers
The elongation is a design choice, set to your process. In one configuration, a 2× Focal Shaper doubles the usable depth of focus for the same optical layout.
Example configuration; elongation up to 5× available. Plotted for λ = 1070 nm, M² = 1.4, f = 255 mm, beam Ø = 12 mm (1/e²). Confirmed per configuration.
Will it fit your setup?
Every Focal Shaper is matched to your laser and process. These are the parameters we design against. Send them and we’ll confirm fit for your exact configuration.
Recommended setup: integrate into a collimated beam with a focusing lens. For setups without a lens, contact us for analysis.
Specifications
| Parameter | Characteristic |
|---|---|
| Focus performance | |
| Elongation of DOF | Up to 5× Gaussian DOF |
| Focus width | Homogenized, reliable and consistent energy distribution |
| Input beam requirements | |
| Input beam | Works with single- or multi-mode |
| Input beam diameter | Customized for beam diameter ±5%; max diameter 16 mm (AOI = 45°) |
| Wavelengths | 1064/1030 nm; 532/515 nm; 450 nm; 355/343 nm; 266 nm; others on request |
| Clear aperture | 2× beam diameter (1/e²) |
| Integration | |
| Alignment | Lateral alignment required |
| Setup | Recommended: integrate into a collimated beam with a focusing lens. For setups without a lens, contact us for analysis. |
| Further specs | |
| Material | Micro-structured dielectric HR coating on fused silica substrate |
| Reflectivity | >99.9% @ 1064/1032 nm; 532/515 nm; 355/343 nm — >99.8% @ 266 nm |
| Dimensions | Ø25 mm/1″ and Ø50 mm/2″. Other dimensions on request. |
Datasheet v1.3. Exact performance depends on wavelength, input beam, M², optical layout and application, confirmed per configuration.
It mounts like a mirror and aligns like an optic.
Parallel / Z-folded
Shaper and a folding mirror before the focusing lens: any distance to the lens, focal length f to the part.
Folded: replaces a mirror
Shaper at 45° folds the beam straight into the lens: takes the place of a deflection mirror already there, no extra space or track length.
Scanner
Shaper ahead of the scanner and F-Theta lens: focus elongation for scanned processing.
Other configurations and angles-of-incidence (AOI) available. Tell us your beam path and we’ll propose the cleanest integration.
Related use cases
Deep 3D ablation in hard metal
7× more stable ablation depth and constant wall angle — no focus tracking.
Read use case →
Robust high-power laser cutting
Consistent cut quality under thermal drift at 10–50 kW+. Free white paper.
Read use case →
Through-Glass Vias for AI packaging
Why 3D beam shaping is the optics-ready foundation for TGV drilling.
Read white paper →More processes we’ve proven; some we can’t show publicly.
Explore all use cases →Where it's used
Welding & Cutting
Controlled energy deposition for stable, high-quality joints.
Explore → Fine structuring, high precisionMicromachining & Precision Structuring
Sharper features and a wider, more forgiving process window.
Explore → TGV / HBM, wafer processingSemiconductor & Advanced Packaging
Depth-of-focus and taper control for wafer processing and TGV drilling.
Explore → One optic, no active focusMarking & Traceability
Consistent mark quality on curved or height-varying parts — no f-Theta, no active focus.
Explore →Frequently asked questions
How much can it extend the depth of focus?
Does it change the beam I already use?
Which lasers and power levels does it support?
All of them: deep-UV to near-IR, femtosecond to continuous-wave, and low power up to 50 kW+. It works with single- or multi-mode sources. Send your wavelength, power/regime, M² and input beam and we confirm fit.
Will it survive multi-kW operation?
That’s a core strength. The optic is all-reflective (a micro-structured dielectric HR coating on fused silica with >99.9% reflectivity), so it stays stable where transmissive optics drift under thermal lensing.
How do I integrate it?
What’s the delivery time?
Custom optics are typically delivered within three weeks, depending on configuration.
Is the Focal Shaper right for your process?
Send us your laser and application. We’ll assess feasibility and get started on the right focus-shaping solution together.
Discuss your challenge