Central to Watt Laser's success is a commitment to precision. Its machines operate at micron and sub-micron levels, where even the smallest deviation can lead to significant downstream failures.
Renishaw encoders deliver laser precision at Watt Laser
Case Study from | Renishaw
Founded in 2020, Watt Laser is a Glasgow-based UK engineering company specializing in high-precision laser systems. The company was born from the vision of a highly experienced laser expert who, after leaving his previous role, wanted to produce innovative surface engineering machines using ultra-short pulse lasers. Starting with just three people, Watt Laser has grown into a dynamic team with a strong emphasis on innovation and agility.
Background
Watt Laser's core mission is to transform high-precision manufacturing by replacing traditional chemical and mechanical processes with cleaner, more efficient laser-based solutions. Its systems are used across sectors including electronics, semiconductor packaging, automotive (including Formula 1), MedTech, and energy. The company's culture is built around empowering young engineers, fostering creativity, and maintaining a startup-like agility even as the company grows.
Central to Watt Laser's success is a commitment to precision. Its machines operate at micron and sub-micron levels, where even the smallest deviation can lead to significant downstream failures. To achieve this level of accuracy and repeatability, Watt Laser relies on Renishaw's encoder technologies, particularly the ATOM™ encoder series and the ADTpro-100 Advanced Diagnostic Tool.
Challenge
Watt Laser's engineering challenges are rooted in the extreme precision required by its customers. Whether manufacturing surface-mount technology (SMT) stencils for circuit boards or welding multi-layer stencil structures, the tolerances are unforgiving.
As Declan Brannagan, Operations Manager at Watt Laser, explains: "In the SMT stencil industry, they cut holes and if that hole is out of position by the width of a human hair, the process falls apart. iPhones don't get made; smartwatches don't get made."
This level of fine precision requires not only high-performance laser systems but also motion control solutions that can eliminate mechanical imperfections such as backlash in ballscrew stages. As Waleed Hafez, Senior Development Engineer at Watt Laser, notes:
"With ballscrew stages, we do get some backlash. With Renishaw encoders, we're able to measure and correct for the backlash in real time."
Another challenge was scalability. Watt Laser needed to streamline its production processes to meet increasing demand without compromising quality. Installation speed and reliability became critical. Fraser Hemming, Senior Product Engineer at Watt Laser, highlights this:
"We needed to get a high-accuracy quality machine to market as quickly as possible."
Additionally, Watt Laser's inspection systems, such as the QC100, required encoder solutions capable of measuring micron-level features.
Solution
Renishaw ATOM encoders
ATOM encoders provide position measurement at fine resolutions, down to 0.1 micron, for ultra-precise motion control. The compact readhead design allows easy integration into custom laser systems and an integrated set-up LED simplifies installation. ATOM readheads feature filtering optics which provide superior signal stability and reliability, essential for maintaining accuracy during multi-pass laser processing.
Hemming explains, “The resolution is appropriate for all our applications. We've managed to increase our throughput of machines by 30% since we started installing the ATOM systems.” Hafez adds, “The ATOM encoder enables us to have fine control over the motion profiles. Our laser path is incredibly smooth and precise, which enables us to have the best products.”
Renishaw ADTpro-100 Advanced Diagnostic Tool
The ADTpro-100 tool offers various functions to enhance encoder installation and maintenance. A color touch screen provides plug-and-play functionality with no need for external software. Comprehensive real-time encoder data is immediately available, including encoder serial number, status, signal size, and signal Lissajous plot. The ADTpro-100 is a portable, handheld diagnostic tool ideal for both manufacturing and in-field optimization or fault-finding.
Hafez describes it as “a useful tool… it makes installation a lot quicker and easier.” He also notes a 30% increase in installation throughput thanks to the ADTpro-100's streamlined set-up process. “It's super easy to use,” Hafez says, “and there's not much training required.”
The content & opinions in this article are the author’s and do not necessarily represent the views of ManufacturingTomorrow
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