Published in Applied Mechanics (MDPI)
Authors: Šárka Němcová, Jan Heřmánek, Pavel Crha, Karolina Macúchová, Václav Němec, Radek Pobořil, Tomáš Tichý, Ondřej Uher, Martin Smrž, Tomáš Mocek
What if optomechanical components – traditionally machined from metals – could be lighter, faster to produce, more affordable, and still sufficiently sturdy and stable for demanding laser applications?
Engineers and scientists from the HiLASE Centre, together with CompoTech, show that this vision is not science fiction, but a practical reality made possible by modern composite 3D printing.
In their newly published article The Use of Composite 3D Printing in the Design of Optomechanical Components, the authors present three case studies demonstrating how composite additive manufacturing can offer advantages that, in some respects, surpass their metal counterparts.
By combining continuous carbon or glass fibres with advanced nylon-based materials, composite 3D printing bridges the gap between conventional polymer prints and machined aluminium. The result is a set of components that deliver:
- significantly lower mass,
- high stiffness,
- strong resistance to vibration,
- rapid design iteration,
- and the ability to reinforce specific areas exactly where needed.
The article highlights three practical examples of composite 3D printing in optomechanics: lightweight and rigid adapter blocks and periscope mounts that substantially reduce mass compared to aluminium designs; protective housings for optical switches that effectively block stray 1030 nm light; and a flexure-integrated mirror mount that enables precise angular adjustment through tailored fibre orientation and localized reinforcement.
This research shows that composite additive manufacturing:
- expands design possibilities,
- enables more compact and lightweight assemblies,
- shortens the path from concept to prototype,
- and reduces the cost of custom optomechanical parts.
Modern composite 3D printing is no longer just a rapid prototyping tool – it is becoming a fully capable method for producing reliable components for advanced laser systems.
This work was cofunded by European Union and the state budget of the Czech Republic under the project LasApp CZ.02.01.01/00/22_008/0004573.
