The Light Tunnel Generator (LTG) is a new beam-shaping technology to significantly improve the efficiency and quality of macro materials processing. The LTG is a thin wafer of fused silica glass with a unique freeform surface. When added to the optics of a process head, it creates a ring-shaped spot that is maintained over a long optical working distance, creating a “light tunnel”. Under appropriate conditions, this long depth-of-focus light tunnel provides a new process parameter space for laser cutting and welding of thick metals. It can produce laser-cut edges with a roughness and dross quality that rivals the most sophisticated multi-spot systems available today – with no loss of process speed and a less sensitive process window. More significant still, this process speed and quality can be achieved under certain conditions using approximately half the laser power of multi-spot systems.