Laser for 3D printing

Abstract

The application provides a laser for 3D printing, comprising a pump source with N channels (N>=2) and N laser processing modules, the N channels of the pump source are connected with the N laser processing modules one by one, and the laser processing modules are used for converting light of the pump source into corresponding laser beams. The pump source of the laser has N output channels, so as to output laser beams with different properties, and the laser beams are converted into corresponding laser beams by corresponding laser processing modules, so that the single laser for 3D printing can output laser beams with different properties, can meet the processing requirements of different processes or different workpieces in the 3D printing process, has low control difficulty, and is beneficial to improving the processing efficiency and keeping the stability and consistency of the processing quality.

Description

Technical Field

[0001] This invention relates to the field of laser technology, and more particularly to a laser for 3D printing. Background Technology

[0002] For manufacturing small quantities of parts with complex internal structures, 3D printing has gradually become the mainstream solution. The mainstream technologies used in 3D printing, such as SLA (solar photopolymerization), SLS (powder bed sintering), and SLM (smoke-lime melting), all require lasers as an energy source.

[0003] Currently, most lasers on the market have only one function, such as continuous fiber lasers, semiconductor lasers, and pulsed lasers. Their output spot size, divergence angle, and temporal characteristics cannot be adjusted over a wide range. However, 3D printing requires lasers with different output characteristics to meet the requirements of different workpieces and processes. The common method is to modulate the spot or split the beam through an external optical path to meet 3D printing needs or improve efficiency. For example, Chinese patent applications 202410858421.1 and 202411416101.7 disclose two methods for modulating the spot through an external optical path to meet the needs of SLA technology 3D printing of different workpieces; Chinese patent application 202423300425.2 discloses a method for improving the efficiency of SLM technology 3D printing through external beam splitting; and Chinese patent application 202511542372.1 discloses a method for heating a substrate to improve the quality of SLM technology 3D printing.

[0004] While the above methods can meet the 3D printing requirements of different workpieces and processes to a certain extent, the external optical path spot modulation method has too high a precision requirement for the modulation mechanism. Environmental changes can easily affect the consistency of the modulation effect, and high power density lasers can easily damage the modulation mechanism, making it unsuitable for large-scale industrial applications. Moreover, for printing processes such as metal powder melting, printing substrate heating, heat treatment of printed parts, and polishing and marking of printed parts, a single-function laser cannot meet all the requirements through external optical path modulation and other methods. Adding lasers or other equipment will not only increase the size of the 3D printer and reduce printing efficiency, but also increase the difficulty of controlling the printing process and reduce the stability and consistency of the 3D printer. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a laser for 3D printing, which can meet the processing requirements of different processes or different workpieces in the 3D printing process, has low control difficulty, and is conducive to improving processing efficiency and maintaining the stability and consistency of processing quality.

[0006] The embodiments of the present invention are achieved through the following technical solutions: A laser for 3D printing includes multiple pump sources with N channels (N≥2) and N laser processing modules. The N channels of the pump sources are connected one-to-one with the N laser processing modules. The laser processing modules are used to convert the light from the pump sources into corresponding laser beams.

[0007] According to a preferred embodiment, the pump source includes a housing, and an assembly cavity is disposed within the housing. The assembly cavity has a first region and a second region. A plurality of semiconductor single tubes are disposed in the first region, and the laser emitted by the plurality of semiconductor single tubes is shaped into a first laser beam, which is transmitted to the second region. A beam splitter is disposed in the second region, which can cut into or out of the transmission path of the first laser beam. When the beam splitter cuts into the transmission path of the first laser beam, it can convert the first laser beam into a second laser beam. At least two output optical fibers are mounted on the sidewall of the housing corresponding to the second region, and the first laser beam and the second laser beam are coupled and output through the output optical fibers.

[0008] According to a preferred embodiment, the beam splitter includes a reflective lens that is adjustablely mounted within the second region.

[0009] According to a preferred embodiment, the reflective mirror has a reflectivity greater than or equal to 0.2%.

[0010] According to a preferred embodiment, the reflector is at least one.

[0011] According to a preferred embodiment, a focusing lens is provided on the upstream side of each output optical fiber.

[0012] According to a preferred embodiment, the beam-splitting assembly includes an aperture stop located upstream of the focusing lens.

[0013] According to a preferred embodiment, the beam splitter further includes a beam expander located upstream of the aperture stop.

[0014] According to a preferred embodiment, the N laser processing modules include at least one semiconductor laser beam combining module, one continuous laser conversion module, and one pulsed laser conversion module.

[0015] According to a preferred embodiment, the output core diameter of the semiconductor laser beam combining module is 100-600µm, the output core diameter of the continuous laser conversion module is 10-100µm, and the pulse width of the pulse laser conversion module is 1-200ns.

[0016] According to a preferred embodiment, the semiconductor laser beam combining module outputs an average power of 10-2000W, the continuous laser conversion module outputs an average power of 10-2000W, and the pulsed laser conversion module outputs an average power of 10-500W.

[0017] According to a preferred embodiment, the N laser processing modules have the same shape.

[0018] The technical solutions of the embodiments of the present invention have at least the following advantages and beneficial effects: The pump source of the laser of this invention has N output channels to output lasers with different properties. These lasers are converted into corresponding laser beams by the corresponding laser processing modules, so that the single 3D printing laser can output laser beams with different properties. This can meet the processing requirements of different processes or different workpieces in the 3D printing process, with low control difficulty, which is conducive to improving processing efficiency and maintaining the stability and consistency of processing quality. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the pump source provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the first embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the second embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the third embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the fourth embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the fifth embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the second region corresponding to the pump source provided in the sixth embodiment of the present invention; Figure 8 A schematic diagram of the structure of the second region corresponding to the pump source provided in the seventh embodiment of the present invention; Figure 9This is a schematic diagram of the structure of a laser provided in an embodiment of the present invention.

[0021] Icons: 1. Pump source; 10. Housing; 101. First output fiber; 102. Second output fiber; 103. Third output fiber; 11. First region; 12. Second region; 13. Semiconductor single tube; 14. Conventional optical shaping component; 15. First laser beam; 151. Second laser beam; 16. Beam splitter; 161. First reflecting mirror; 162. Second reflecting mirror; 163. First motor; 164. Second motor; 165. First focusing lens; 166. Second focusing lens; 167. Third focusing lens; 168. Aperture; 169. Beam expander; 2. Laser; 21. Pump control unit; 22. Pump unit; 23. Optical processing unit; 231. Semiconductor laser beam combining module; 232. Continuous laser conversion module; 233. Pulsed laser conversion module; 24. Light emitting unit; 241. Emitting head. Detailed Implementation

[0022] To better understand and implement this invention, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0024] Please refer to Figure 9 A 3D printing laser 2 includes multiple pump sources 1 with N channels (N≥2) and N laser processing modules. Each of the N channels of the pump source 1 is connected to one of the N laser processing modules. The laser processing modules convert the light from the pump source 1 into corresponding laser beams. The pump source 1 has N output channels to output lasers with different properties. These laser beams are converted into corresponding laser beams by the laser processing modules, enabling the single 3D printing laser 2 to output laser beams with different properties. This allows it to meet the processing requirements of different processes or workpieces in 3D printing, with low control difficulty, which helps improve processing efficiency and maintain the stability and consistency of processing quality.

[0025] like Figure 9As shown, the 3D printing laser 2 includes a pump control unit 21, a pump unit 22, a light processing unit 23, and a light emission unit 24. The pump unit 22 includes multiple pump sources 1 with N channels (N≥2), the light processing unit 23 includes N laser processing modules, and the light emission unit 24 includes N emission heads 241. Specifically, the pump sources 1 are connected to the pump control unit 21, and the N channels (output optical fibers or output channels) of the pump sources 1 are connected to the corresponding laser processing modules. The laser beams converted by the laser processing modules are output through the corresponding emission heads 241.

[0026] More specifically, the pump control unit 21 has a signal control unit and a power control unit. The signal control unit is used to control the channel selection of each pump source 1 in the pump unit 22 and to analyze and process the monitoring signals of the pump source 1 during operation. The power control unit is used to control the output power of each pump source 1 in the pump unit 22 and to provide the power required by the pump source 1. The pump control unit 21 and the pump unit 22 are connected by a network cable, a multi-core communication line, and a power transmission line for signal interaction and power transmission between the two units. The pump source 1 in the pump unit 22 is used to convert electrical energy into semiconductor pumped laser, and the power of the semiconductor pumped laser output through each channel is controlled by the pump control unit 21. Each laser processing module in the optical processing unit 23 is connected to different channels of each pump source 1 in the pump unit 22 through optical fiber fusion splicing to guide the semiconductor pumped laser into the laser processing module for conversion.

[0027] In a preferred embodiment, such as Figure 9As shown, among the N laser processing modules, at least one semiconductor laser beam combining module 231, one continuous laser conversion module 232, and one pulsed laser conversion module 233 are included. Correspondingly, the pump source 1 has at least three channels, i.e., N≥3. Here, we use N=3 for explanation, meaning the light processing unit 23 in the 3D printing laser 2 includes one semiconductor laser beam combining module 231, one continuous laser conversion module 232, and one pulsed laser conversion module 233. In use, when a semiconductor pump laser from the pump unit 22 enters the semiconductor beam combining module through channel one, the semiconductor beam combining module operates, generating a combined semiconductor laser output. Similarly, when a semiconductor pump laser from the pump unit 22 enters the continuous laser conversion module 232 through channel two, the continuous laser conversion module 232 operates, generating a converted single-mode / multi-mode continuous laser output. When a semiconductor pump laser from the pump unit 22 enters the pulsed laser conversion module 233 through channel three, the pulsed laser conversion module 233 operates, generating a converted pulsed laser output. The output head 241 is connected to the laser processing module via fiber optic fusion splicing to export the laser output from the laser processing module, thereby extending the working distance of the laser 2 and matching the external optical path structure. The laser beams output from the three channels have different properties and can be used for different processes and different workpieces in 3D printing. The laser beams output from the three channels can be selected to emit light from one or more channels simultaneously according to actual needs, and the required power, waveform and other conventional parameters can be adjusted.

[0028] The transmitter 241 can be equipped with standard interfaces such as QBH, QD, QCS, and collimation output isolator, depending on the application scenario and interface standard. Non-standard interfaces can also be customized.

[0029] Preferably, the output core diameter of the semiconductor laser beam combining module 231 is 100-600um, the output core diameter of the continuous laser conversion module 232 is 10-100um, and the pulse width of the pulse laser conversion module 233 is 1-200ns.

[0030] Preferably, the semiconductor laser beam combining module 231 outputs an average power of 10-2000W, the continuous laser conversion module 232 outputs an average power of 10-2000W, and the pulsed laser conversion module 233 outputs an average power of 10-500W.

[0031] In this embodiment, the semiconductor beam combining module is used to convert the semiconductor pump laser into a flat-top laser with a large output core diameter for substrate heating and laser heat treatment processes in 3D printing; the continuous laser conversion module 232 is used to convert the semiconductor pump laser into single-mode or multi-mode Gaussian lasers with different output core diameters for metal powder melting processes in 3D printing. By using a variety of continuous laser conversion modules 232 with different core diameter ratios, the output core diameter of the continuous laser can be flexibly switched for different workpieces and parts to improve 3D printing efficiency; the pulsed laser conversion module 233 is used to convert the semiconductor pump laser into lasers with different output core diameters and output in pulse mode. The characteristics of pulsed lasers are high peak power and short interaction time with the workpiece, which are used for polishing and marking processes in 3D printing.

[0032] Preferably, the N laser processing modules have the same shape. As mentioned above, the structural dimensions and cooling channels of the semiconductor laser beam combining module 231, the continuous laser conversion module 232, and the pulsed laser conversion module 233 can be unified to achieve rapid integration and replacement of different modules.

[0033] Preferably, the laser processing module can be stacked in number with the same attributes to improve the processing efficiency of a single process, such as using multiple semiconductor laser beam combining modules 231 to improve the heating efficiency of the printing substrate or the heat treatment efficiency of the printed parts, and using multiple continuous laser conversion modules 232 to improve the printing efficiency of metal powder melting.

[0034] Next, we will introduce pump source 1 with N channels (N≥2). It is understood that N is a positive integer.

[0035] Please refer to Figures 1 to 8 A pump source 1 includes a housing 10, within which an assembly cavity is disposed. The assembly cavity has a first region 11 and a second region 12. A plurality of semiconductor single tubes 13 are disposed in the first region 11. The laser emitted by the plurality of semiconductor single tubes 13 is shaped into a first laser beam 15, which is transmitted to the second region 12. A beam splitter 16 is disposed in the second region 12. The beam splitter 16 can cut into or out of the transmission path of the first laser beam 15. When the beam splitter 16 cuts into the transmission path of the first laser beam 15, it can convert the first laser beam 15 into a second laser beam 151. At least two output optical fibers are mounted on the sidewall of the housing 10 corresponding to the second region 12. The first laser beam 15 and the second laser beam 151 are coupled and output through the output optical fibers. Figure 1As shown, the laser emitted by the semiconductor single tube 13 is shaped by a conventional optical shaping component 14 to form a first laser beam 15. In use, the beam splitting component 16 can select to cut into or out of the transmission path of the first laser beam 15 according to actual needs, so that the pump source 1 can output at least two laser beams with different properties. The pump source 1 of this invention internally splits the beam, enabling a single pump source 1 to divide energy time-sharingly and output laser beams to at least two laser conversion modules through at least two output optical fibers. Each output optical fiber, i.e., the fiber channel model, matches the requirements of different laser conversion modules, allowing a single pump source 1 to drive multiple laser conversion modules, effectively reducing the cost of the laser 2.

[0036] It should be noted that the conventional optical shaping component 14 includes a fast-axis collimating lens (FAC), a slow-axis collimating lens (SAC), a polarizing beam combiner, etc., which are conventional technologies. They are used to shape the laser emitted by several semiconductor single tubes 13 into a first laser beam 15, which is consistent with the laser beam shaping principle of the conventional ground pump source 1, and will not be described in detail here.

[0037] In this embodiment, the beam splitter 16 includes a reflector lens, which is adjustablely mounted within the second region 12. At least one reflector lens is used. Depending on the reflectivity of the reflector lens, the first laser beam 15 is transmitted or reflected to form a second laser beam 151. The reflectivity of the reflector lens is greater than or equal to 0.2%.

[0038] In this embodiment, a three-channel pump source 1 (three output optical fibers) is used as an example for illustration. Specifically, as follows... Figures 2 to 4 As shown, the housing is provided with a first output optical fiber 101, a second output optical fiber 102 and a third output optical fiber 103, and the beam splitter 16 includes two reflective mirrors, specifically a first reflective mirror 161 and a second reflective mirror 162. The reflectivity of the first reflective mirror 161 and the second reflective mirror 162 is greater than or equal to 99.9%, that is, the first reflective mirror 161 and the second reflective mirror 162 are total reflection mirrors.

[0039] In some embodiments, such as Figure 2 As shown, in this embodiment, both the first reflecting lens 161 and the second reflecting lens 162 cut out the transmission path of the first laser beam 15, and the first laser beam 15 is coupled out through the first output optical fiber 101.

[0040] In some embodiments, such as Figure 3 As shown, in this embodiment, the first reflecting mirror 161 cuts into the transmission path of the first laser beam 15, and the second reflecting mirror 162 cuts out the transmission path of the first laser beam 15. At this time, the first laser beam 15 is converted into the second laser beam 151 by the reflection of the first reflecting mirror, and the second laser beam 151 is coupled out through the third output optical fiber 103.

[0041] In some embodiments, such as Figure 4 As shown, in this embodiment, the first reflecting mirror 161 and the second reflecting mirror 162 are both cut into the transmission path of the first laser beam 15. At this time, the first laser beam 15 is reflected by the first reflecting mirror and the second reflecting mirror in sequence and converted into the second laser beam 151. The second laser beam 151 is coupled out through the second output optical fiber 102.

[0042] In the above three embodiments, pump source 1 simultaneously outputs a laser beam with one property.

[0043] like Figure 5 and Figure 6 As shown, the reflectivity of the first reflecting lens 161 is 66.6%, and the reflectivity of the second reflecting lens 162 is 50%.

[0044] Specifically, such as Figure 5 As shown, in this embodiment, the first reflecting mirror 161 cuts into the transmission path of the first laser beam 15, and the second reflecting mirror 162 cuts out the transmission path of the first laser beam 15. At this time, the first laser beam 15 is converted into two second laser beams 151 at the first reflecting mirror 161. That is, part of the first laser beam 15 passes through the first reflecting mirror 161 and is coupled out through the first output fiber 101, and part of the first laser beam 15 is reflected by the first reflecting mirror 161 and coupled out through the third output fiber 103. In this embodiment, the output ratio of the first output fiber 101 to the second output fiber 102 is 1:2. The pump source 1 can output two laser beams simultaneously.

[0045] like Figure 6 As shown, in this embodiment, both the first reflecting mirror 161 and the second reflecting mirror are inserted into the transmission path of the first laser beam 15, and... Figure 5 Unlike the pump source 1 shown, the laser beam reflected by the first reflecting mirror 161 is partially projected and partially reflected at the second reflecting mirror 162. That is, in this embodiment, the first laser beam 15 is converted into three second laser beams 151, which are respectively coupled and output through the first output fiber 101, the second output fiber 102, and the third output fiber 103. The output ratio of the first output fiber 101, the second output fiber 102, and the third output fiber 103 is 1:1:1. In this embodiment, the pump source 1 can output three laser beams simultaneously to meet the processing requirements of different working conditions.

[0046] It should be noted that both the first reflecting mirror 161 and the second reflecting mirror 162 can be driven by motors mounted on the housing to adjust their angles, thereby enabling the first reflecting mirror 161 and the second reflecting mirror 162 to enter and exit the transmission path of the first laser beam 15, thus switching the number and properties of the laser beam output from the pump source 1. Specifically, the first motor 163 is used to drive the first reflecting mirror 161, and the second motor 164 is used to drive the second reflecting mirror 162.

[0047] In this embodiment, a focusing lens is provided on the upstream side of each output fiber. The focusing lens is used to focus the first laser beam 15 or the second laser beam 151 to couple it to the corresponding output fiber. Specifically, the first output fiber 101 corresponds to the first focusing lens 165, the second output fiber 102 corresponds to the second focusing lens 166, and the third output fiber 103 corresponds to the third focusing lens 167.

[0048] like Figure 7 As shown, the beam splitter 16 includes an aperture stop 168, which is located upstream of the focusing lens. In this embodiment, the reflectivity of the first reflecting mirror 161 and the second reflecting mirror 162 is greater than or equal to 99.9%, making them total reflection mirrors. Both the first reflecting mirror 161 and the second reflecting mirror 162 are inserted into the transmission path of the first laser beam 15. Optionally, the aperture stop 168 is a φ8, NA0.15 aperture stop 168. In this case, the second output fiber 102 is a small core diameter output fiber, which can be a 135μm / NA0.22 output fiber.

[0049] Furthermore, such as Figure 8 As shown, the beam splitter 16 also includes a beam expander 169, which is located upstream of the aperture stop 168. In this embodiment, the reflectivity of the first reflecting mirror 161 and the second reflecting mirror 162 is greater than or equal to 99.9%, making them total reflection mirrors. The first reflecting mirror 161 cuts into the transmission path of the first laser beam 15, and the second laser beam 151 cuts out of the transmission path of the first laser beam 15. After being reflected by the first reflecting mirror 161, the first laser beam 15 passes sequentially through the beam expander 169 and the aperture stop 168 to form the second laser beam 151. The second laser beam 151 is focused by the third focusing mirror 167 and then coupled to the third output fiber 103 for output. Optionally, the third output fiber 103 is a 220μm / 0.15 output fiber.

[0050] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications are also considered within the scope of protection of this invention.

Claims

1. A laser for 3D printing, characterized in that, It includes multiple pump sources with N channels (N≥2) and N laser processing modules. The N channels of the pump source are connected one-to-one with the N laser processing modules. The laser processing modules are used to convert the light from the pump source into corresponding laser beams.

2. The laser for 3D printing according to claim 1, characterized in that, The pump source includes a housing, and an assembly cavity is disposed inside the housing. The assembly cavity has a first region and a second region. A plurality of semiconductor single tubes are disposed in the first region. The laser emitted by the plurality of semiconductor single tubes is shaped into a first laser beam, and the first laser beam is transmitted to the second region. A beam splitting component is provided in the second region. The beam splitting component can cut into or out of the transmission path of the first laser beam. When the beam splitting component cuts into the transmission path of the first laser beam, the beam splitting component can convert the first laser beam into a second laser beam. At least two output optical fibers are mounted on the side wall of the outer casing corresponding to the second region, and the first laser beam and the second laser beam are coupled and output through the output optical fibers.

3. The laser for 3D printing according to claim 2, characterized in that, The beam splitter includes a reflective lens, which is adjustablely mounted within the second region.

4. The laser for 3D printing according to claim 3, characterized in that, The reflectivity of the reflective lens is greater than or equal to 0.2%.

5. The laser for 3D printing according to claim 3, characterized in that, There is at least one reflector.

6. The laser for 3D printing according to claim 2, characterized in that, A focusing lens is provided on the upstream side of each output optical fiber.

7. The laser for 3D printing according to claim 6, characterized in that, The beam-splitting assembly includes an aperture stop, which is located upstream of the focusing lens.

8. The laser for 3D printing according to claim 7, characterized in that, The beam splitter also includes a beam expander, which is located upstream of the aperture stop.

9. The laser for 3D printing according to claim 1, characterized in that, The N laser processing modules include at least one semiconductor laser beam combining module, one continuous laser conversion module, and one pulsed laser conversion module.

10. The laser for 3D printing according to claim 9, characterized in that, The semiconductor laser beam combining module has an output core diameter of 100-600µm, the continuous laser conversion module has an output core diameter of 10-100µm, and the pulse width of the pulse laser conversion module is 1-200ns.

11. The laser for 3D printing according to claim 9, characterized in that, The semiconductor laser beam combining module outputs an average power of 10-2000W, the continuous laser conversion module outputs an average power of 10-2000W, and the pulsed laser conversion module outputs an average power of 10-500W.

12. The laser for 3D printing according to claim 1, characterized in that, All N laser processing modules have the same shape.

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