Delphi gets $3.7 million to develop “heatless laser” machining

ROCHESTER, N.Y.—Delphi Automotive received a $3.7-million grant from the U.S. Department of Energy (DOE) to develop a versatile, energy-efficient method for micro-machining complex shapes.

This ultrafast (femtosecond) laser manufacturing process will enhance production of flow control holes in Delphi’s gas direct injection (GDi) fuel injectors.

When pulses from a femtosecond laser hit metal or polymer, the target material is instantly vaporized, transferring no heat to the part.

This process will increase laser machining energy efficiency up to 25 per cent while eliminating secondary processes such as etching, deburring and surface cleaning.

Delphi is partnering with Raydiance, Inc. and Microlution, Inc. to develop this new system at Delphi’s Rochester facility.

“This project has energy-saving implications and applicability across numerous industries and our working relationship with the Department of Energy is critical to advancing these important initiatives,” said Jeffrey Owens, chief technology officer at Delphi Automotive.

Delphi Automotive PLC supplies electronics and technologies for automotive, commercial vehicle and other market segments from technical centers, manufacturing sites and customer support facilities in 30 countries.

Raydiance develops precision femtosecond laser manufacturing solutions to the medical, consumer and industrial markets.

Chicago-based Microlution Inc. builds machine tools optimized for the fabrication of small, high precision parts.