As diode pumped solid state lasers gain more market share, the performance, stability and lifetime of the diode pump source faces unprecedented scrutiny. Lifetimes of diode pumps in excess of 35,000 hrs are sought with no intervention or maintenance from the end user. One lifetime and power limiting phenomena for arrays is that of solder creep typical with traditional mounting using soft solders such as Indium. Harder solders such as Gold/Tin on Copper-Tungsten submounts provide a more robust and stable mounting system for long term high power pump sources. Furthermore, beam multiplexing of laser bars require tight wavelength and polarization purity which are affected by mounting induced strain. In this investigation, high power 940 nm laser bars, operating in the 100 to 200 W power range, were mounted using AuSn/CuW and In soldering schemes. The differences in thermal and strain characteristics are investigated through the examination of the emitter wavelength, nearfield measurements, polarization and smile. The measurements are correlated with finite element modeling to predict the 3-dimensional thermal distributions within the laser bars.

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Developing laser processes for industrial applications is a challenging and laborious task. Conventional controllers for laser scan systems lack the ability to predict the actual path of the laser beam on the workpiece, making extensive trial‐and‐error testing of different parameters and delay settings necessary in order to achieve satisfactory results. Finding a balance between the accuracy achieved and throughput is typically a compromise, and varies from user to user. Thanks to the introduction of SCANmotionControl, a new software solution by Scanlab, the programming of laser processes has been revolutionized.

Modern ultra‐short‐pulse (USP) laser systems are fostering new micro‐machining technologies. Hole drilling with high aspect ratios has become a particularly important application in several industries. But drilling straight walls with high aspect ratios is not feasible if the laser beam impacts specimens at a normal incidence angle. The beam caustic affects hole corners and limits the maximum aspect ratio — that's why new solutions are needed. A novel 5‐axis technology allows beam inclination and enables straight walls, as well as negatively tapered holes.