Advanced 3D-Printed Beam Dump Developed Under LASER-PRO Project: A Czech Collaboration Milestone
A cutting-edge beam dump for high-power laser applications has been successfully developed under the LASER-PRO project through a collaboration between two Czech consortium members – the HiLASE Centre and CARDAM. The new solution combines advanced geometry optimization with additive manufacturing techniques, delivering improved thermal performance and design compactness compared to conventional approaches.
Precision Meets Performance
The beam dump – a critical component designed to safely absorb residual laser radiation – was engineered to meet the demanding requirements of high-energy laser operations. Using computational modelling and 3D printing, the team developed a laser beam dump fabricated via 3D printing, featuring mathematically optimized geometries designed to efficiently transfer heat from the absorber body into a cooling fluid. This combination ensures both structural integrity and thermal efficiency, even under intense laser loads. The HiLASE beam dump was experimentally tested with 10000 laser shots, each at 1 joule energy, with a 1064 nm wavelength and a 2 mm beam diameter.
Test parameters:
- Cooling water flow: 4 litres/minute
- Water temperature: 13 °C
- Concave lens inserted: No
Key contributions:
- HiLASE led the external design of the beam dump, focusing on outer geometry and dimensions to ensure maximal absorption efficiency.
- CARDAM was responsible for designing the internal heat-dissipation structure, applying mathematical optimization to determine the ideal shape and density for thermal transfer.
The resulting component leverages an internal mathematical architecture produced via metal additive manufacturing, enabling both structural stability and effective thermal conductivity.
Verified Results from Experimental Testing
According to the evaluation data (as listed in the internal technical sheets), the prototype underwent a series of tests under operational laser loads. The results confirmed the beam dump’s ability to sustain prolonged exposure to high laser energy levels while maintaining stable temperature levels across its surface.
Measurements demonstrated:
- Uniform thermal distribution across the absorber’s core
- Consistent performance at high repetition rates
- Minimal deformation under extended laser exposure
These outcomes validate the effectiveness of both the thermal design and manufacturing method used.
Strategic Contribution to LASER-PRO Objectives
This development directly supports several strategic goals of the LASER-PRO project, funded under Horizon Europe’s Excellence Hubs initiative. It represents a successful technology demonstrator in the field of sustainable manufacturing and thermal management – two areas prioritized within the project’s innovation agenda.
The collaboration also exemplifies the project's core values:
- Translating research into functional prototypes
- Strengthening cooperation between research centres and SMEs
- Promoting regional industrial innovation
The project team expresses appreciation for the combined expertise and dedication of all contributors, including:
Pavel Crha, Marek Böhm, Jan Šmaus, Jan Heřmánek, Jakub Horáček, Pavel Gruber, Martin Gášek, Jakub Krupa, Jason Iwachow, and Ondřej Kurkin.
A Platform for Broader Impact
The LASER-PRO project brings together 18 partners from Czechia, Lithuania, and Ukraine in a joint effort to boost the European laser ecosystem. This beam dump innovation is a clear example of how cross-disciplinary cooperation can deliver practical, high-performance solutions for industry.
More breakthroughs are expected as the consortium continues to pilot advanced technologies across laser processing, biomedical applications, semiconductor manufacturing, and 3D printing.
