Position Synchronized Output (PSO)

By Aerotech, Inc.

To solve the limitations of time-based firing, Aerotech developed Position Synchronized Output (PSO), a hardware-based synchronization technology that fundamentally redefines how lasers are triggered. PSO shifts the paradigm from time-based firing to distance-based firing, effectively creating a "pulse at a specific location” architecture. PSO acts as a high-speed, deterministic link between the laser's output trigger and the physical position feedback of the individual motion axes. Using closed-loop, high-resolution encoder feedback operating in the MHz range, PSO tracks the exact physical location of the laser on the work piece in real-time. The Automation1 software-based machine controller calculates the vector distance traveled along the programmed path and commands the laser to fire only when a specific, user-defined distance threshold has been crossed. Because PSO is tied directly to physical distance, the spot spacing remains perfectly equidistant and consistent regardless of the velocity or acceleration of the motion system. If the scanner decelerates to navigate a sharp corner, the laser pulse frequency automatically scales down, maintaining a constant fluence and preventing thermal damage. The technical implementation of PSO within the Automation1 architecture operates with nanosecond precision. It supports up to 3-axis PSO across all drives, seamlessly integrating both physical servo motion (like linear and rotary stages) and galvanometer mirror motion into a single synchronized firing algorithm. This allows manufacturers to control the specific amount of optical energy deposited at any given micrometer along a three-dimensional path, empowering complex micromachining operations.