Whenever maximum processing speed is essential in industrial laser processing, polygon scanners demonstrate their particular strengths. Unlike systems with galvanometric mirrors, which are designed for flexible beam movements, polygon scanners focus on continuously deflecting the laser beam along a line – but with very high repetition rates and stability. They deliver excellent results in manufacturing processes where large areas need to be structured or cleaned. 

A polygon scanner consists of a rotating, faceted polygon wheel with a small planar mirror on each facet that deflects the incoming laser beam. The continuous rotation of this polygon body guides the laser beam in a line across the processing field. Unlike galvanometer scanners, the beam position cannot be flexibly changed or stopped. Instead, the polygon scanner generates a uniform, line-by-line deflection at a constant speed.

This makes this scanner technology ideal for applications where line structures need to be applied quickly and with a high degree of uniformity. These include, for example, laser structuring in battery production, the removal of thin layers during the cleaning of foils, or the direct exposure of printed circuit board layouts.

Polygon scanners stand out thanks to their high line repetition rate. In systems with a high laser pulse rate, this allows precise, uniform line patterns to be applied without mechanical delays or direction changes disrupting the process. The exact and reproducible path guidance ensures consistent results over long production cycles.

Especially in series production, this continuity offers a clear advantage. In addition, polygon scanners are particularly durable because their rotary motion makes them mechanically simpler and less susceptible to wear.

Polygon scanners can demonstrate their strengths particularly well in automated production environments.

Typical advantages for increasing efficiency include:

• Short cycle times: The consistent rotation allows very high deflection speeds and thus faster processing cycle times. In addition, the time between two consecutive lines is reduced compared to galvo systems, as the dead time during facet changes is significantly shorter than a return jump or reversal using a galvo.
• Consistent processing quality: Since no acceleration or deceleration phases are necessary, uniform structures are created without irregularities.
• Lower thermal stress on the component: The uniform movement prevents hot spots and supports stable processes with low component stress.
• High reproducibility: The precise repetition of the line paths leads to consistent results even in longer series runs.

These features make polygon scanners a valuable component wherever productivity, stability, and repeatability are important.

When selecting a suitable polygon scanner, speed is not the only factor to consider. The requirements of the application must be precisely matched to the optical, mechanical, and control characteristics of the scanner. The following aspects are particularly important:

Wavelength and mirror coating

Polygon scanners must be adapted to the laser wavelength used. The reflective coating of the mirrors varies depending on the IR, VIS, or UV application—both in terms of reflectivity and thermal resistance.

RAYLASE has many years of experience in the battery cell manufacturing, electronics, display technology, and packaging industries and is familiar with the specific requirements of these markets in detail. We have been developing high-precision scanning systems for these markets for many years. These include various hybrid solutions that combine different deflection technologies. This expertise makes us a strong partner in the design and integration of high-performance laser systems.

Are you planning to use a polygon scanner or would you like to further develop your laser processes in a targeted manner? Then get in touch! The RAYLASE team will support you with a technology-neutral and practical approach.