Photovac Laser – Worldwide

Understanding Optical Pitting in Sealed RF Laser Tubes and Differences in Laser Cavity Designs 

Sealed RF-excited CO₂ lasers are widely used for industrial engraving, cutting, and marking applications. However, one of the most significant challenges in these lasers is optical pitting caused by RF excitation. This issue arises due to metal sputtering from the RF electrodes inside the laser cavity, which contaminates and degrades the optics over time. 

While all RF CO₂ lasers operate on the same fundamental principle, the cavity design and RF excitation method vary across manufacturers, leading to different performance characteristics and longevity. In this post, we’ll explore the difference between Synrad, Epilog, and Iradion laser cavities and their RF strip technologies. 

How Optical Pitting Occurs in RF-Excited CO₂ Lasers 

• RF Excitation & Electrode Sputtering:
  Sealed CO₂ lasers use RF excitation to ionize the gas mixture, but over time, the high-energy RF plates begin to degrade, releasing microscopic particles. 

• Contaminant Buildup on Optics:
  These particles settle on cavity mirrors and output couplers, leading to optical pitting, where the mirror coatings erode. 

• Performance Decline:
  As optics degrade, power output drops, and the beam profile becomes irregular, leading to loss of precision and cutting efficiency. 

Comparing Laser Cavity Designs: Synrad vs. Epilog vs. Iradion 

1. Synrad Laser Cavity Design

• Synrad pioneered waveguide RF laser tubes, using aluminum or ceramic cavity construction. 

• They employ separate RF electrode strips, where the excitation occurs along the length of the tube. 

• The downside is that metallic RF plates are exposed to gas discharge, making them susceptible to sputtering, which accelerates optical pitting. 

• While Synrad tubes are known for reliability, long-term sputtering eventually degrades optics, reducing output power. 

2. Epilog Laser Cavity Design

• Epilog sources its CO₂ laser tubes from other manufacturers, like Synrad or Coherent, but integrates them into its own closed-loop cooling and optical system. 

• These lasers use an all-metal RF electrode system, similar to Synrad, but in some cases, tubes are not designed for long-term reprocessing. 

• As a result, when optical pitting occurs, repair options are limited, often leading to full tube replacement rather than regassing or electrode refurbishment. 

3. Iradion Laser Cavity Design

• Iradion lasers stand out due to their fully ceramic resonator construction, eliminating direct metal RF strip exposure to the gas discharge. 

• This prevents metal sputtering and optical pitting, significantly extending the lifespan of the optics. 

• Unlike metal waveguide designs, the ceramic cavity provides: 

• Higher purity of gas mixture, reducing contamination. 

• More uniform RF distribution, leading to improved beam quality and stability. 

• As a result, Iradion lasers experience less optical degradation and require fewer replacements over time. 

• One major consideration is the constant heating and cooling of the ceramic core. This leads to micro fracturing of the ceramic and weakens the ceramic material and the attached optical ends. Over time this can lead to seal leaks around the optics and micro-fissures in the ceramic material leading to leaks.  

Understanding RF Strip Technology in CO₂ Lasers 

The RF strip is a critical component in RF-excited CO₂ lasers, responsible for generating and sustaining the gas plasma needed for lasing. Different manufacturers implement RF technology in unique ways: 

Synrad RF Technology 

• Uses traditional RF electrode strips positioned along the tube walls. 

• These strips degrade over time, leading to RF plate sputtering and eventual optical pitting. 

• When power drops, optics become contaminated, and beam performance worsens. 

Epilog RF Technology 

• Since Epilog integrates third-party laser tubes, its RF design depends on the manufacturer (often Synrad or Coherent-based designs). 

• Typically, standard metal electrode RF strips are used, leading to similar sputtering issues over time. 

Iradion RF Technology 

• Uses ceramic waveguide technology, where the RF excitation does not involve exposed metal surfaces inside the cavity. 

• This eliminates sputtering-related optical pitting, leading to longer lifespan and more stable power output. 

• RF strips are integrated into the ceramic structure, reducing degradation compared to metal-based systems. 

 

Conclusion: Why Some Laser Tubes Last Longer Than Others 

While all sealed RF CO₂ lasers degrade over time, the design of the laser cavity and RF excitation system plays a crucial role in longevity: 

• Synrad & Epilog lasers, with metal-based RF electrodes, are prone to sputtering, which causes optical pitting and power loss. 

• Iradion’s ceramic cavity design eliminates metal sputtering, resulting in less optical degradation and extended tube life. 

For industrial users looking for longer-lasting, more stable CO₂ lasers, choosing a ceramic-based laser system like Iradion can significantly reduce the risks of optical pitting and premature failure. 

For further information contact Christopher Zelich Co2 Laser Electroptics-Electronics Engineer. 

Understanding the Challenges of Repairing the Coherent GEM100 CO₂ Laser and D1000 RF Exciter 

The Coherent GEM100 CO₂ laser is a widely used industrial laser known for its high precision and power stability. It operates in conjunction with the D1000 RF exciter, which provides the necessary radio frequency (RF) energy to ionize the CO₂ gas mixture and sustain laser operation. However, over time, these systems face critical issues that make repairs extremely difficult, if not impossible. 

Why the GEM100 CO₂ Laser Becomes Non-Repairable 

One of the most significant failure points of the GEM100 laser is electrical sputtering of the RF plates located inside the laser cavity. This process leads to severe degradation of cavity optics, resulting in: 

1. Micro-Particle Contamination 

1. The RF plates inside the cavity degrade over time due to high-voltage RF excitation. 

1. This degradation causes metal sputtering, releasing tiny conductive particles inside the laser cavity. 

1. These particles settle on internal optics, including mirrors and output couplers. 

1. Optical Damage & Pitting 

1. The accumulation of sputtered particles on optical surfaces leads to pitting. 

1. Pitted optics lose their reflectivity and transmission efficiency, significantly reducing the laser’s ability to generate a clean, high-power beam. 

1. The result is a non-concentric, distorted, or non-uniform laser beam output, which affects precision cutting and engraving applications. 

1. Power Loss & Beam Instability 

1. As the optics degrade, laser power output drops significantly. 

1. The beam profile becomes irregular, reducing accuracy in applications requiring a highly focused and collimated beam. 

1. Collimating optics further struggle to correct the beam due to its deformed shape. 

Regassing Alone Is Not a Solution 

Many users believe that regassing the laser tube can restore performance. However, this is often not enough to return the GEM100 to optimal efficiency. 

• Why? The primary issue isn’t just the depletion of the gas mixture; it’s the physical damage to the laser cavity and optics caused by prolonged RF plate sputtering. 

• Regassing a laser with damaged optics and cavity contamination will only result in continued poor performance. 

• Additionally, RF-related issues such as exciter inefficiencies and degraded electrodes contribute to ongoing failures. 

Conclusion 

While it is technically possible to attempt repairs on a failing Coherent GEM100 CO₂ laser, the reality is that extensive optical and cavity damage caused by RF plate sputtering often renders the system beyond economic repair. 

• Low power output, poor beam quality, and RF excitation failures make restoration challenging. 

• Even if regassed, a laser with pitted optics and cavity contamination will still underperform. 

For businesses relying on these lasers, replacement or upgrading to a newer system is often the most practical long-term solution. 

For further information, Contact Photovac Laser Corporation, Christopher Zelich, Co2 Laser/Electroptics Engineer. 

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We have two META BEAM 4C units available for sale, each equipped with a 400-watt laser, cutting table, software, computer, and monitor. These units are in excellent condition and ready for immediate delivery. Capable of cutting up to 0.90″ metal and 1.0″ acrylic, they offer great versatility for your cutting needs.

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Delivery and setup: $7,500
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Call 614.875.3300
Sales@photovaclaser.com

Dear Valued Customer,

We at Photovac Laser are proud to have been your trusted partner for many years, providing reliable backup solutions for your older Synrad model lasers. The Synrad FSF201, known for its durability and consistent performance, has been a cornerstone of many operations.

Recently, Photovac Laser has enhanced its capabilities by remanufacturing the FSf201 model with brand-new laser tubes. Our upgraded laser tubes feature new plates, optics, and insulators, addressing the most common points of failure in RF laser tubes. With these improvements, you can count on our remanufactured lasers to deliver exceptional performance for years to come.

Trust Photovac Laser to meet your full-service needs with our commitment to quality and reliability. Contact us today to learn more about how we can support your operations.

Best regards,

Christopher Zelich
President, Photovac Laser

The recent price increase in regas costs by Epilog has made our services more valuable than ever. With 28 years of experience, Photovac Laser Worldwide is your professional, one-stop solution for repairing Epilog lasers. Unlike other companies, we are fully qualified to service your Epilog laser, possessing the necessary components to replace circuit boards and optics.

Many competitors charge less because they lack the expertise and parts, often returning lasers that are less operational. Don’t be misled by unqualified providers. Verify any company’s credentials with the Better Business Bureau in your state before entrusting them with your laser; you may be surprised at what you find. Trust Photovac Laser Worldwide for reliable, professional laser repairs.

Dear Epilog Laser Users;

Recently, Epilog Laser, based in Golden, Colorado, informed its dealers of a price increase for their laser regas service. The cost for regassing an Epilog 50-watt laser has risen by $400 to $2600, representing a 16% increase. In contrast, Photovac Laser continues to provide regas and remanufacture services for all Epilog brand laser tubes at significantly lower rates than those of Epilog Laser. We service all makes, brands, and models, and we invite you to contact us today at Sales@photovaclaser.com

Dear Chris and team;

Thank you for the excellent service! We got the laser Friday and we installed it yesterday with no hiccups. Laser has been running great since. 
Cesar

Important Announcement for Coherent Laser Tube Users
If you are currently using Coherent Incorporated laser tubes, including the industrial Coherent G100 and Coherent E150, or the medical Coherent G100M (Laser System), for your medical encore laser system and have been informed that the manufacturer no longer services these models, we have a vital update for you.
Photovac Laser Corporation, the leading third-party specialist in industrial and medical laser tube remanufacturing, is fully equipped and committed to supporting all Coherent laser model tubes. Our extensive expertise and dedicated service extend the life of your laser investment, ensuring operational efficiency and reliability for years to come.
KERN Laser Systems, utilizes Coherent E150 Co2 laser tube in their lower powered cutting systems. KERN now offers their own proprietary laser tube as a replacement to the Coherent E150. Why spend $25,000, plus further power supply and mounting updates, when you can buy a newly remanufactured laser tube for 2/3rds less the cost from Photovac Laser. WHY? When you buy a KERN laser tube, you cannot reliably upkeep the laser when it malfunctions prematurely. There is no software access to you, the customer, to perform routine maintenance to the laser cavity, RF control circuitry, and optical shaping delivery system. Your ONLY option is to accept an exchange for $21,000.00, and you must return the old core for this option. WHY?
Vytek Laser Systems uses Coherent E150 in its laser cutting tables. Photovac is its supplier for repairs to the Coherent E150 laser tubes.
Comprehensive Support & Maintenance ⛑
Photovac Laser prides itself on a vast inventory, including all necessary components like optics, electronics, electrodes, and seals. We utilize proprietary regassing procedures. These resources enable us to offer unparalleled repair and maintenance services, guaranteeing your laser tubes’ performance for the next fifteen years.
Our Technical Prowess
Our capabilities are not limited to mere part replacements. Photovac Laser possesses in-depth technical knowledge and hands-on experience with every Coherent carbon dioxide laser tube model. This includes, but is not limited to:
• Precision Calibration: Ensuring your laser operates at its optimal performance level.
• Electronics and Optics Expertise: From intricate electronic repairs to precision optics alignments, our technicians handle every detail with utmost care.
• Custom Regassing Procedures: Our proprietary regassing techniques restore your laser’s power and efficiency, significantly prolonging its life. Our optical and boiling laser mixture typically provides 15% more power than Coherent’s original installed laser tube.
• Emergency Exchange Service: Understanding the critical nature of your operations, Photovac Laser maintains a stock of lasers for immediate exchange to minimize downtime for our customers.
Why Choose Photovac Laser Corporation?
• Four Decades of Specialized Experience: Focusing on Coherent laser tubes, we’ve honed our skills to provide solutions that the original manufacturer no longer offers. Photovac Laser has been remanufacturing Coherent laser tubes for over thirty of our forty years in business.
• Why trust someone else? Photovac Laser is truly the only one outside of the OEM with the technical expertise for Coherent Co2 lasers. Others say they do it, but it is only a lie. How do you trust a person thinking they can regas a laser when Photovac Laser has had all the tools and knowledge necessary for repairs for 40 years?
• Ready Inventory for Quick Turnarounds: Our extensive stock of parts and complete laser systems ensure swift service and repair, reducing operational interruptions.
• Commitment to Quality and Reliability: Our services are designed to extend the lifespan of your lasers and ensure they continue to deliver the precision and reliability you expect.
Reach Out for Support
Do not let service discontinuation slow you down. Photovac Laser Corporation supports your Coherent laser tubes with expert care, comprehensive services, and a commitment to your operational success. Contact us today to learn how we can help you maintain your laser systems for years to come.
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This message emphasizes Photovac Laser Corporation’s commitment to quality, its extensive inventory for quick services, and its capability to handle any Coherent CO2 laser tube. It reassures customers of a reliable service alternative to the original manufacturer.