Metal clad active fibres for power scaling and thermal management at kW power levels

We present a new approach to high power fibre laser design, consisting of a polymer-free all-glass optical fibre waveguide directly overclad with a high thermal conductivity metal coating. This metal clad active fibre allows a significant reduction in thermal resistance between the active fibre and the laser heat-sink as well as a significant increase in the operating temperature range. In this paper we show the results of a detailed thermal analysis of both polymer and metal coated active fibres under thermal loads typical of kW fibre laser systems. Through several different experiments we present the first demonstration of a cladding pumped aluminium-coated fibre laser and the first demonstration of efficient operation of a cladding-pumped fibre laser at temperatures of greater than 400 °C. Finally, we highlight the versatility of this approach through operation of a passively (radiatively) cooled ytterbium fibre laser head at an output power of 405 W in a compact and ultralight package weighing less than 100 g.