Design and assembly of a miniaturized high-power laser bar to 50 µm fiber coupling module

Miniaturized optical systems that couple light from broad area or trapezoid diode laser bars with cw powers up to 100 W into fibers with core diameters between 50 µm and 100 µm have been developed and assembled on smart Direct-Copper-Bond (DCB) system platforms that incorporate active cooling structures as well as hermetic housing facilities. The approach for a fast and flexible joining of the optical elements by a flux-free applied solder is to jet liquid solder spheres onto joining geometries, thus enabling for creating complex shaped solder joint geometries with high accuracies