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Use cases/Use case/Robust high-power laser cutting
Use case · 3D Gaussian

Robust high-power laser cutting, even as the optics heat up.

At 10–50 kW and beyond, thermal lensing shifts the focus and the cut drifts: kerf width fluctuates, burr rises, quality degrades over long paths. Focal Shaping extends the effective focal range and stabilizes the axial energy delivery, so the process stays in spec across a shift. A lever for machine builders pushing next-generation cutting systems.

Product: 3D Gaussian Application: Laser cutting Power: 10–50 kW+ For: Machine OEMs
The challenge
  • At 10–50 kW, even small thermal lensing in collimator or focusing optics shifts the focal position
  • A few hundred micrometres of focus drift are enough to degrade performance and eat into overall equipment effectiveness (OEE)
  • Real-world effects: fluctuating kerf width, more burr and melt instability, quality loss over long paths, and more recalibration
The solution
  • An engineered phase front creates a stable axial intensity distribution over a larger z-range, instead of one tight focal point
  • Strong reduction of thermal-drift sensitivity; stable energy delivery under thermal load
  • All-reflective micro-structured mirror technology, supporting 50 kW+
Instead of relying on a single tight focus, the optic holds a usable beam across a larger axial range: a more robust way to run high-power cutting.
Source: Midel Photonics white paper, Focal Shaping: A Novel 3D Beam Shaping Technology for Robust High-Power Laser Cutting.
Shaped vs. unshaped focus at the cutting nozzle: the shaped beam holds ~2× Rayleigh length of usable focus, with a flatter beam causticAt the cutting nozzle, the shaped beam maintains about twice the Rayleigh length of usable depth of focus versus an unshaped beam, and the beam-diameter-versus-z caustic is far flatter around the focal region
Benefits for cutting machine OEMs

Four levers for a next-generation cutting system

Consistent cut quality under thermal drift

Stable kerf width and reduced burr formation, with improved robustness for aluminium, copper and thicker materials, and less sensitivity to heat accumulation.

A larger axial process window

More forgiving to nozzle distance and material variation, fewer interruptions for parameter tuning, and reduced dependence on autofocus compensation across a full shift.

High-power-ready architecture

Built for 10–50 kW systems and beyond, with stable performance even at high feed rates, removing a key limit on high-power system productivity.

Easy drop-in integration

Placed in the collimated beam, it simply replaces a folding mirror inside the head: no realignment, no mechanical or software changes, and compatible with standard cutting heads.

Impact reported in the white paper: higher uptime, reduced scrap and rework, lower service effort, stable performance at high speeds, and clear differentiation in a competitive OEM market.

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Building a high-power cutting system?

Tell us your laser, power level and head. We’ll assess how Focal Shaping fits and start a pilot together.

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