The focusing lens of a CO2 laser is positioned at the end of a long chain of delicate and expensive optics which direct the laser beam at the target---a sheet of steel---under thousands of watts of power. The focusing lens, which can cost anywhere from $500 to $3000, seals the rest of the laser system's equally expensive optics from the sparks, smoke and particles ( known as "spatter") thrown off during the cutting or welding process while it also focuses the beam at the target. As the focusing lens gets dirty, the quality of the weld or cut degenerates because the lens and its delicate anti-reflective coating begin to absorb laser energy. As energy is absorbed by the lens it delivers less power and it heats up and begins to distort the focus. Weld or cut quality then degrades.

Eventually, the laser focusing lens must be replaced due to the power loss and focus distortion caused by spatter damage. If the lens is not replaced, it will absorb so much laser power that it will melt or explode, thereby rupturing the barrier that shields the rest of the system optics and causing a catastrophic failure of the CO2 laser system which results in extensive downtime as well as a very expensive repair.

Protective windows have been used to protect against welding spatter for many years. But, until ICL developed a new way of mounting them, protective windows worked only in low pressure environments such as welding. Under high pressure these protective windows will fail unless something is done to prevent breakage. CO2 laser cutting systems use assist gas under pressure to aid in the cutting process. Before the engineers at ICL's Lens Savers® Division created a technical solution to the problem, the high gas pressure used in cutting had made it impossible to use lens protection windows. ICL's patent pending pressure bypass lens mounting method has now made it possible to use Lens Savers® protective windows in all CO2 laser cutting systems. Lens Savers® adapters or lens mounts let the pressure within the cutting head equalize on both sides of the protective window. A cavity is formed between the Lens Savers® window and the lens which is allowed to pressurize. There is another high pressure area on the opposite side of the Lens Savers® window where the assist gas is being used to enhance the cut. Since both areas are under high pressure, with the Lens Savers® window sandwiched in the middle, the window is effectively under zero pressure and does not break.

ICL's engineers have now designed a full line of window and lens mounts and adapters that allow CO2 laser users to put a Lens Savers® window into a system without any modifications except the addition of the mount or adapter. They have created an assortment of ingenious ways to squeeze Lens Savers® into the confined spaces where focusing lenses are typically positioned. Lens Savers® adapters are available for all major CO2 laser systems, including
Amada, Bystronic, Cincinnati, Laser Lab, Mazak, Mitsubishi, Strip-it and Trumpf .