Additive manufacturing printhead

Abstract

To provide a print head for an additive manufacturing apparatus.SOLUTION: There is provided a print head for an additive manufacturing apparatus. The print head includes a housing (130). A projection element (116) is disposed within the housing (130) and is configured to receive one or more laser beams from a beam emitter and project a plurality of projected laser beams (118) in a pattern (122). A consolidating optic part (124) is disposed within the housing (130) and is disposed below the projection element (116). The consolidating optic part (124) is configured to consolidate the pattern (122) of the plurality of projected laser beams (118) into a consolidated pattern of projected laser beams (126).SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present specification relates generally to additive manufacturing devices, and more particularly to self-contained printheads that deliver one or more laser beams to a build plane of an additive manufacturing device. [Background technology]

[0002] Additive manufacturing devices can be used to build objects layer by layer from build materials such as organic or inorganic powders. Additive manufacturing methods include, for example, laser powder bed fusion systems. In some applications, additive manufacturing devices use one or more scanner assemblies, each containing a fiber laser, a collimator, an adjustable beam focusing assembly, and a mirror mounted on a galvanometer, to focus and scan the laser beam over a build plane to melt or fuse the build material at the build plane. These scanner assemblies are expensive and difficult to service and maintain. The consolidation rate of the build material can only be increased slightly due to the heat load and soot generated by adding additional scanner assemblies. Summary of the Invention [Problem to be solved by the invention]

[0003] Therefore, there is a need for an additive manufacturing device that includes a more economical, self-contained print head that is utilized to manipulate multiple laser beams to melt or fuse build material at a build plane. [Means for solving the problem]

[0004] One aspect of the present disclosure is a print head of an additive manufacturing device, the print head including: a housing; a projection element disposed in the housing, the projection element configured to receive one or more laser beams generated by a beam emitter and project a plurality of projected laser beams in a pattern; and an integrating optical component disposed in the housing and below the projection element, the integrating optical component configured to integrate the pattern of the plurality of projected laser beams into an integrated pattern of projected laser beams. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 schematically illustrates a side view of an additive manufacturing apparatus including a print head according to one or more embodiments shown and described herein. [Figure 2] 2A and 2B schematically illustrate perspective views of a print assembly including the printhead of FIG. 1 according to one or more embodiments shown and described herein. [Figure 3] FIG. 3 schematically illustrates a side view of the print head of FIG. 2 used with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein. [Figure 4] 4A-4C are schematic depictions of a top view of the image plane and the consolidated image plane produced by the projection element and integrated optics, respectively, of the printhead of FIG. 3 according to one or more embodiments shown and described herein; [Figure 5] 2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 6] 2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 7] 2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 8]2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 9] 2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 10] 2A and 2B are schematic illustrations of a side view of another print head for use with the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein; [Figure 11] 2A-2C schematically depict a flow diagram for delivering multiple laser beams to a build plane of the additive manufacturing apparatus of FIG. 1 according to one or more embodiments shown and described herein. DETAILED DESCRIPTION OF THE INVENTION

[0006] The embodiments illustrated in the drawings are exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of exemplary embodiments can be understood when read in conjunction with the following drawings, in which like structure is indicated with like reference numerals and in which:

[0007] The embodiments described herein are directed to a self-contained print head that includes one or more light sources of varying power and / or wavelength. This print head can be used in conjunction with an additive manufacturing device to fuse powdered build material using multiple laser beams instead of the traditional single-beam approach per scanner. This method is more energy efficient and generates less soot in the additive manufacturing device. Furthermore, compared to traditional scanners, this process is cheaper, more robust, and can be calibrated before installation. Additionally, the print head is modular, allowing the build area of ​​the additive manufacturing device to be increased by adding additional modules. Because only enough energy is applied to melt the powder, additional modules can be added without soot concerns and with reduced material ejection from the welding zone. In this way, the print head is scalable to increase the consolidation rate of the powdered build material and the size of parts that can be produced by the additive manufacturing device. Beam shaping, coupling, steering, and delivery optics for powder processing and pre- and post-heating of the welding area are contained within the print head.

[0008] A print head generally includes a housing, a beam emitter for generating one or more laser beams, a projection element disposed within the housing configured to receive the one or more laser beams and project the multiple laser beams in a pattern, and integrating optics configured to integrate the pattern of the multiple laser beams into an integrated pattern of laser beams. In some embodiments, the beam emitter is disposed within the housing. In other embodiments, the beam emitter is disposed outside the housing and is a laser source coupled to a delivery medium (e.g., fiber) that delivers one or more laser beams to the housing. In further embodiments, the beam emitter is a laser source disposed outside the housing, and the beam emitter delivers one or more laser beams to the housing through free space. The print head provides an apparatus for irradiating multiple laser beams to a build plane of an additive manufacturing device. Various embodiments of methods for delivering multiple laser beams to a build plane and a print head, as well as the operation of the methods for delivering multiple laser beams to a build plane and a print head, are described in more detail herein. Whenever possible, the same reference numbers are used throughout the drawings to refer to the same or similar parts.

[0009] Unless otherwise expressly stated, it is never intended that any method described herein be construed as requiring its steps to be performed in a particular order or as requiring a particular orientation of any device. Thus, if a method claim does not actually recite an order in which its steps should be followed, or if any apparatus claim does not actually recite an order or orientation for individual components, or if it is specifically stated otherwise in the claim or description that the steps are to be limited to a particular order or no particular order or orientation for the apparatus components is recited, then no order or orientation is intended to be inferred in any respect. This applies to any possible implicit basis for interpretation, including matters of logic regarding the arrangement of steps, operational flow, component order, or component orientation, plain meaning derived from grammatical organization or punctuation, and the number or type of embodiments described herein.

[0010] As used herein, the singular forms "a," "an," and the like include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "one" element includes aspects having two or more such elements unless the context clearly dictates otherwise.

[0011] Referring now to FIG. 1 , a manufacturing apparatus 10 is shown in accordance with one or more embodiments described herein. The manufacturing apparatus 10 may generally include a build area or build platform 14, a supply platform 16, a recoat assembly 18, and a print assembly 20. The recoat assembly 18 and the print assembly 20 are coupled to rails 26 of the manufacturing apparatus 10 and configured to translate along the rails 26 in response to actuation of a first actuator assembly 28. The first actuator assembly 28 may be configured to facilitate independent control of the recoat assembly 18 and the print assembly 20 along a work axis 30 of the manufacturing apparatus 10. The work axis 30 is also referred to herein as the “longitudinal axis” (i.e., extending along the X-axis of the coordinate system as shown in the figure). This allows the recoat assembly 18 and the print assembly 20 to traverse the work axis 30 of the manufacturing apparatus 10 in the same and / or opposite directions, and allows the recoat assembly 18 and the print assembly 20 to traverse the work axis 30 of the manufacturing apparatus 10 at different and / or the same speed.

[0012] In the embodiment described herein, the build platform 14, supply platform 16, recoat assembly 18, and print assembly 20 are arranged in series along a work axis 30 of the manufacturing apparatus 10 between a home position 34 of the print assembly 20 located near the −X end of the work axis 30 and a home position 32 of the recoat assembly 18 located near the +X end of the work axis 30. In the embodiment, the build platform 14 is arranged between the home position 34 of the print assembly 20 and the supply platform 16 along the work axis 30 of the manufacturing apparatus 10.

[0013] In embodiments, the second actuator assembly 36 may be configured to facilitate independent control of the print assembly 20 along a horizontal axis (i.e., extending along the + / - Y axis of the coordinate system as shown) that is generally perpendicular to the vertical axis (i.e., the work axis 30). The first actuator assembly 28 and the second actuator assembly 36 are generally referred to as the printhead position control assembly. That is, the printhead position control assembly includes the first actuator assembly 28 configured to move the printhead along the vertical axis and the second actuator assembly 36 configured to move the printhead along the horizontal axis. The printhead position control assembly may be controlled via signals generated by a controller 38, such as an electronic control unit. The electronic control unit may include a processor and non-transitory computer-readable memory.

[0014] Print assembly 20 characteristically includes a support bracket 40 and one or more printheads 104. Support bracket 40 is movably coupled to rail 26 and first actuator assembly 28 of manufacturing apparatus 10, and printheads 104 are movably coupled to support bracket 40 via second actuator assembly 36.

[0015] As described below, manufacturing apparatus 10 is used to scan a build plane 54 of one or more workpieces (not shown) disposed within manufacturing apparatus 10 with one or more electromagnetic radiation beams 106 (e.g., laser beams) emitted from a print head 104. Additionally, manufacturing apparatus 10 is used to additively print one or more layers (i.e., use additive manufacturing techniques) on each of the scanned workpieces.

[0016] As used herein, the term "additive manufacturing" or "additive manufacturing technique or method" refers to a manufacturing process in which successive layers of material are deposited on top of each other to build a three-dimensional component layer-by-layer. The successive layers are melted or fused to form a monolithic or integrated part.

[0017] In some embodiments, manufacturing apparatus 10 uses a powder bed fusion (PBF) technique, such as direct metal laser melting (DMLM) or direct metal laser sintering (DMLS). In such embodiments, layers of the workpiece are additively printed by melting or fusing a first layer of build material or powder 48 to build plane 54, melting or fusing a second layer of powder on top of the first layer, etc. However, in some embodiments, the workpiece may be additively printed by melting or fusing a single layer of powder to build plane 54. Additionally, in alternative embodiments, manufacturing apparatus 10 may use any other suitable additive manufacturing technique or process.

[0018] The recoat assembly 18 is constructed to facilitate dispensing of powder 48 onto the build platform 14 and supply platform 16. The build platform 14 is coupled to a build platform actuator 50, which facilitates raising and lowering the build platform 14 in a direction perpendicular to the work axis 30 of the manufacturing apparatus 10 (i.e., parallel to the + / -Z axes of the coordinate axes shown in the figures). The build platform 14 and build platform actuator 50 are disposed within a build container 52 located below the work axis 30 of the manufacturing apparatus 10 (i.e., in the -Z direction of the coordinate axes shown in the figures). During operation of the manufacturing apparatus 10, the recoat assembly 18 fills the build container 52 with powder 48 until the powder 48 forms a build plane (shown as a line) 54. The recoat assembly 18 then spreads a layer of powder 48 across the build plane 54. The layer of powder 48 is then melted or fused along the build plane 54 using an electromagnetic radiation beam 106 to form a first layer of the workpiece. The build platform 14 is then lowered (e.g., as indicated by the arrow) and the recoat assembly 18 spreads another layer of powder 48 across the build plane 54. This layer can then be fused or melted to the first layer using one or more laser beams 106 to form a second layer of the workpiece, and so on.

[0019] 1 , the supply platform 16 is coupled to a supply platform actuator 56, which facilitates raising and lowering the supply platform 16 in a vertical direction (i.e., parallel to the + / −Z axes of the coordinate system shown in the figure) relative to the work axis 30 of the manufacturing apparatus 10. The supply platform 16 and supply platform actuator 56 are disposed within a supply bin 58 located below the work axis 30 of the manufacturing apparatus 10 (i.e., in the −Z direction of the coordinate system shown in the figure). During operation of the manufacturing apparatus 10, the supply platform 16 is raised relative to the supply bin 58 toward the work axis 30 of the manufacturing apparatus 10 by operation of the supply platform actuator 56 after a layer of powder 48 is dispensed from the supply platform 16 onto the build platform 14.

[0020] The print assembly 20 is configured to direct one or more laser beams 106 onto the layer of powder 48 on the build platform 14 as the print assembly 20 traverses the build platform 14 along the work axis 30 of the manufacturing apparatus 10. Generally, the print head 104 generates and directs the one or more laser beams 106 at the build plane 54, thereby melting / melting the powder 48 spread across the build platform 14.

[0021] As shown, in some embodiments, each print head 104 includes a beam emitter 108. More specifically, as described in further detail below, the beam emitter 108 emits one or more laser beams 106 that are ultimately directed to specific locations on the build plane 54. In this regard, when additively printing a workpiece, the print head 104 scans the laser beam 106 over a portion of the build plane 54 where it is desired to melt or fuse the powder 48 to form a layer of the workpiece. Additionally, as described in further detail below, each print head 104 may include one or more components configured to collimate, focus, and direct the emitted laser beam 106.

[0022] The manufacturing apparatus 10 can include any suitable number of print heads 104. For example, in the illustrated embodiment, the manufacturing apparatus 10 includes one print head 104. However, in alternative embodiments, the manufacturing apparatus 10 can include two print heads 104 or three or more print heads 104. The multiple print heads 104 can be arranged in a variety of configurations, including linear and / or staggered, along the X-axis and / or Y-axis directions.

[0023] Continuing with reference to FIG. 1 , the manufacturing apparatus 10 may further include a controller 38 communicatively coupled to the first actuator assembly 28, the second actuator assembly 36, the recoat assembly 18, and / or the print assembly 20. In an embodiment, the controller 38 is coupled to the manufacturing apparatus 10 via a communication conduit 64. However, it should be understood that in other embodiments, the controller 38 may be communicatively coupled to the manufacturing apparatus 10 via various other means or systems, such as, for example, via a wireless connection. The controller 38, which may also be referred to as an electronic control unit, comprises a processor and a non-transitory memory having computer-readable and executable instructions stored thereon. Any operation of the manufacturing apparatus 10, including those described herein, may be performed by the computer-readable and executable instructions stored in the non-transitory memory of the controller 38 when executed by the processor of the controller 38. For example, one or more actuators may be actuated by the computer-readable and executable instructions stored in the non-transitory memory of the controller 38 when executed by the processor of the controller 38 to operate the print assembly 20.

[0024] In an embodiment, controller 38 may be further communicatively coupled to computing device 65, optionally via network 66 or directly via a communications link such as a wired or wireless connection point. Computing device 65 may be configured to perform processes such as generating executable instructions for building components using manufacturing apparatus 10, such as by implementing a CAD or other related three-dimensional drafting and rendering system, as well as a slicing engine, etc.

[0025] Additionally, in some embodiments, a computing device 65 may be communicatively coupled to the print head 104 via a communication conduit 64. Accordingly, the computing device 65 may be configured to control the operation of the print head 104 such that one or more laser beams 106 are generated, focused, and scanned across the build plane 54. The computing device 65 also receives data from the print head 104 related to the position of the beams 106 relative to the build platform 14 as the beams 106 are scanned across the build plane 54.

[0026] 1 is provided solely to place the present subject matter in an exemplary field of use. As such, the present subject matter may be readily adaptable to any type of additive manufacturing machine, including additive manufacturing machines that use a variety of additive manufacturing techniques.

[0027] FIG. 2 is a perspective view of a portion of a print assembly 20 according to one embodiment of the present invention. The print assembly 20 is coupled to the rail 26 of the manufacturing apparatus 10, as described above. The portion of the print assembly 20 shown here is the print head 104. The print head 104 includes a housing 130 that protects one or more components configured to collimate, focus, and direct the emitted laser beam 106. Additionally, a soot collection system 140 is mounted on the exterior of the housing 130 and includes one or more soot collection tubes 142a, 142b connected to one or more soot collection heads 144a, 144b, respectively. The soot collection heads 144a, 144b are positioned on either side of the print head 104 and are positioned proximate the build plane 54 to collect soot generated during powder melting / melting. The soot collection heads 144a, 144b also include geometric features to provide a laminar flow of process gas across the build plane 54 at a velocity that removes soot but leaves the surface of the build plane 54 undisturbed. The soot collection tubes 142a, 142b subsequently transport the soot from the build plane 54 to an appropriate filter or collection container (not shown). In some embodiments, a computing device 65 may be communicatively coupled to the print head 104. Accordingly, the computing device 65 may be configured to control the operation of the print head 104 so that the soot collection system 140 can function as described herein.

[0028] 3 is a cross-sectional side view of one embodiment of a print head 104 according to the present invention, which is self-contained and generally includes optical components configured to collimate and focus an emitted laser beam 106 onto the build plane 54. In particular, the print head 104 includes one or more beam emitters 108 optically coupled to a collimator 110, which is optically coupled to a beam homogenizer 112, which is optically coupled to turning optics 114, which is optically coupled to a projection element 116 (e.g., a special light modulator (“SLM”)), which is optically coupled to imaging optics 120, which are optically coupled to integrating optics 124. In some embodiments, the beam emitter 108 is a fiber-coupled laser diode. Additional components within the self-contained print head 104 include an energy recovery device 128 optically coupled to the projection element 116. Each of the beam emitter 108, collimator 110, beam homogenizer 112, turning optics 114, projection element 116, imaging optics 120, integrating optics 124, and energy recovery device 128 is at least partially mounted within a housing 130 using appropriate brackets and / or fasteners (not shown). The housing 130 has a front surface 132, a top surface 134, a back surface 136, and a bottom surface 138.

[0029] The beam emitter 108 generally extends along the top surface 134 of the housing 130 and is configured to generate a laser beam 106 of sufficient energy to at least partially melt the powder at the build plane 54. In some embodiments, the beam emitter 108 is disposed within the housing 130. In other embodiments, the beam emitter is disposed outside the housing 130 and is a laser source (not shown) coupled to a delivery medium (e.g., fiber) that delivers one or more laser beams into the housing. In some embodiments, the beam emitter 108 can include any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, a yttrium-based solid-state laser or a CO laser. Additionally, although the print head 104 is shown and described as including a single beam emitter 108, the print head 104 can include two or more beam emitters. In one embodiment, for example, the print head 104 may include a first beam emitter having a first power output or wavelength, a second beam emitter having a second power output or wavelength that is different from the first laser power output or wavelength, or at least two beam emitters having substantially the same power output and wavelength. In yet other embodiments, the print head 104 may include any combination of beam emitters that enables the manufacturing apparatus 10 to function as described herein. In some embodiments, a computing device 65 may be communicatively coupled to the print head 104. Accordingly, the computing device 65 may be configured to control the operation of the beam emitter 108 such that the print head 104 can function as described herein.

[0030] During operation of the print head 104, the beam emitter 108 initially transmits the laser beam 106 to a collimator 110 located at the distal end of the beam emitter 108 and proximate the rear surface 136 of the housing 130. The collimator 110 is configured to convert the high-divergence laser beam output by the fiber-coupled beam emitter 108 into a well-collimated, parallel, low-divergence beam using a lens system (not shown) aligned with the fiber-coupled beam emitter 108.

[0031] After collimation by the collimator 110, the laser beam 106 has a round Gaussian or near-Gaussian energy distribution or profile and is delivered to the beam homogenizer 112. The beam homogenizer is generally located below the collimator 110 and also adjacent to the backside 136 of the housing 130. The beam homogenizer 112 converts the round Gaussian profile of the collimated laser beam 106 into one having a uniform energy distribution that matches the projection element 116. In other words, after homogenization by the beam homogenizer 112, the laser beam 106 has a uniform energy distribution.

[0032] After homogenization by the beam homogenizer 112, the laser beam 106 with a uniform energy distribution is directed to the turning optics 114. The turning optics 114 are generally located below the beam homogenizer 112 and adjacent to the backside 136 of the housing 130. In some embodiments, the turning optics 114 are dielectric mirrors or prisms. The turning optics 114 redirect the laser beam 106 with a uniform energy distribution to the projection element 116.

[0033] When the laser beam 106 having a uniform energy distribution reaches the projection element 116, the projection element 116 projects multiple laser beams 118 having a pattern of laser light that forms an image or line. The projection element 116 is generally disposed adjacent to the top surface 134 of the housing 130 between its front surface 132 and rear surface 134. Additionally, the projection element 116 is disposed above the turning optics 114. The projection element 116 is coupled to a cooling element 117 for cooling the projection element 116 from heat generated by the energy of the laser beam 106. In some embodiments, the projection element 116 is a digital micromirror device (“DMD”). In other embodiments, the projection element 116 is a liquid crystal display (“LCD”) projector, a liquid crystal on silicon (“LCOS”) projector, or other SLM. In some embodiments, a computing device 65 can be communicatively coupled to the print head 104. Accordingly, computing device 65 may be configured to control the operation of print head 104 so that projection elements 116 can function as described herein. In particular, computing device 65 may be configured to control the pattern of multiple laser beams projected by projection elements 116.

[0034] Furthermore, when the laser beam 106 having a uniform energy distribution reaches the projection element 116, the projection element 116 directs a portion of the laser beam 106 to an energy recovery device 128. The energy recovery device 128 is generally disposed adjacent to a front surface 132 of the housing 130 and located below the projection element 116. In some embodiments, the energy recovery device 128 is a heat sink or heat exchanger. The energy recovery device 128 is configured to recover any energy not used by the projection element 116. In some embodiments, the energy recovered by the energy recovery device 128 is used for preheating or post-heating the powder 48. In other embodiments, the energy recovery device 128 includes a photovoltaic cell (not shown) that generates power from the energy recovered by the energy recovery device 128 and can be reused within the manufacturing apparatus 10. In a further embodiment, the energy recovery device 128 is a beam dump that removes the energy recovered by the energy recovery device 128 from the manufacturing apparatus 10.

[0035] The multiple laser beams 118 generated by the projection element 116 are then directed to imaging optics 120 located below the projection element 116. The imaging optics 120 are comprised of transmissive or reflective elements that modify the magnification of the pattern formed by the multiple laser beams 118 into an expanded pattern of laser beam 122. For example, referring to FIG. 4, a top view of the expanded pattern of laser beam 122 to form an image having a rectangular image plane "A" is shown. However, it should be understood that the expanded pattern of laser beam 122 may form any image having image planes of multiple different shapes or sizes, as desired.

[0036] The imaging optics 120 deliver the magnified pattern of the laser beam 122 to the integrating optics 124. The integrating optics 124 are positioned below the imaging optics 120 and adjacent the bottom surface 138 of the housing 130. In some embodiments, the integrating optics 124 are cylindrical lenses or focusing diffractive optics. The integrating optics 124 are used to integrate the magnified pattern of the laser beam 122 into an integrated pattern of the laser beam 126 at the build plane 54. For example, referring to FIG. 4 , a top view of the integrated pattern of the laser beam 126 to form an image having a linear image plane “B” is shown. However, it should be understood that the integrated pattern of the laser beam 126 can form any image having image planes of multiple different shapes or sizes, as desired. Thus, the print head 104 scans the integrated pattern of the laser beam 126 over the portion of the build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece.

[0037] 5 is a cross-sectional side view of another embodiment of a print head 204 according to the present invention, where the print head 204 is self-contained and generally includes optical components configured to collimate and focus one or more radiation beam(s) 206a-206c onto the build plane 54. It should be understood that the print head 204 can be used in conjunction with the manufacturing apparatus 10 in a manner substantially similar to the print head 104 described above.

[0038] In particular, print head 204 includes multiple beam emitters 208a-208c optically coupled to multiple collimators 210a, 210b, 210c, which are optically coupled to beam homogenizer 212 optically coupled to turning optics 214, which are optically coupled to projection element 216 (e.g., SLM), which is optically coupled to imaging optics 220, which are optically coupled to integrating optics 224. In some embodiments, beam homogenizer 212 is a single homogenizer configured to homogenize each laser beam 206a-206c in the same manner. In other embodiments, beam homogenizer 212 includes multiple beam homogenizers 212, each configured to separately homogenize a respective one of laser beams 206a-206c. Additional components within self-contained print head 204 include an energy recovery device 228 optically coupled to projection element 216. Each of the plurality of beam emitters 208a-208c, the plurality of collimators 210a-210c, the beam homogenizer 212, the turning optics 214, the projection element 216, the imaging optics 220, the integrating optics 224, and the energy recovery device 228 is at least partially mounted within a housing 230 using appropriate brackets and / or fasteners (not shown). The housing 230 has a front surface 232, a top surface 234, a back surface 236, and a bottom surface 238.

[0039] The plurality of beam emitters 208a-208c are configured to generate laser beams 206a-206c, respectively, of sufficient energy to at least partially melt the powder at the build plane 54. The plurality of beam emitters are generally arranged along a top surface 234 of the housing 230 and adjacent a back surface 236 thereof. Like the print head 104 described above, in some embodiments, the beam emitters 208-208c may comprise any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, a yttrium-based solid-state laser or a CO laser. As shown in FIG. 5, in some embodiments, the plurality of beam emitters 208a-208c may include a first beam emitter 208a having a first power output or wavelength, a second beam emitter 208b having a second power output or wavelength that is different from the first laser power output or wavelength, and a third beam emitter 208c having a third power output or wavelength that is different from the first and second laser power outputs or wavelengths.

[0040] During operation of the print head 204, the plurality of beam emitters 208a-208c first provide laser beams 206a-206c to the plurality of collimators 210a-210c, respectively. The plurality of collimators 210a-210c are generally disposed below the plurality of beam emitters 208a-208c and adjacent to the rear surface 236 of the housing 230. The plurality of collimators 210a-210c are configured to convert each of the high-divergence laser beams 206a-206c output by the beam emitters 208a-208c into a well-collimated, parallel, low-divergence beam using a lens system (not shown).

[0041] After collimation by the multiple collimators 210a-210c, the laser beams 206a-206c have a round Gaussian or near-Gaussian energy distribution or profile and are delivered to a beam homogenizer 212. The beam homogenizer 212 is generally disposed below the multiple collimators 210a-210c and adjacent to the back surface 236 of the housing 230. The beam homogenizer 212 converts the round Gaussian profile of each of the collimated beams 206a-206c to have a uniform energy distribution that matches the projection element 216. The beam homogenizer 212 then combines each of the laser beams 206a-206c into a single laser beam 206.

[0042] After homogenization by the beam homogenizer 212, the single laser beam 206 having a uniform energy distribution is delivered to turning optics 214. The turning optics 214 are generally located below the beam homogenizer 212 and adjacent to the backside 236 of the housing 230. In some embodiments, the turning optics 214 are dielectric mirrors or prisms. The turning optics 214 redirect the laser beam 206 having a uniform energy distribution toward the projection element 216.

[0043] When the laser beam 206 having a uniform energy distribution reaches the projection element 216, the projection element 216 projects a plurality of laser beams 218 having a pattern of laser light that forms an image or a line. The projection element 216 is generally disposed adjacent to the top surface 234 of the housing 230 between its front surface 232 and rear surface 234. In some embodiments, the projection element 216 is an SLM. The projection element 216 is coupled to a cooling element 217 for cooling the projection element 216 from heat generated by the energy of the laser beam 206.

[0044] Furthermore, when the laser beam 206 having a uniform energy distribution reaches the projection element 216, the projection element 216 directs a portion of the laser beam 206 to an energy recovery device 228. The energy recovery device 228 is generally disposed adjacent to a front surface 232 of the housing 230 and located below the projection element 216. In some embodiments, the energy recovery device 228 is a heat sink or heat exchanger. The energy recovery device 228 is configured to recover energy not used by the projection element 216. In some embodiments, the energy recovered by the energy recovery device 228 is used for preheating or post-heating the powder 48. In other embodiments, the energy recovery device 228 includes a photovoltaic cell (not shown) that generates power from the energy recovered by the energy recovery device 228 and can be reused within the manufacturing apparatus 10. In a further embodiment, the energy recovery device 228 is a beam dump that removes the energy recovered by the energy recovery device 228 from the manufacturing apparatus 10.

[0045] The multiple laser beams 218 generated by the projection element 216 are then directed to imaging optics 220 positioned below the projection element 216. The imaging optics 220 are comprised of transmissive or reflective elements that modify the magnification of the pattern formed by the multiple laser beams 218 into an expanded pattern of laser beams 222. For example, the expanded pattern of laser beams 222 may form an image similar to the expanded pattern of laser beam 122 described above with respect to printhead 104 (FIG. 3).

[0046] Imaging optics 220 deliver the magnified pattern of laser beam 222 to integrating optics 224. Integrating optics 224 are typically located below imaging optics 220 and adjacent bottom surface 238 of housing 230. In some embodiments, integrating optics 224 are cylindrical lenses or focusing diffractive optics. Integrating optics 224 are used to integrate the magnified pattern of laser beam 222 into an integrated pattern of laser beam 226 at build plane 54. For example, the integrated pattern of laser beam 226 may form an image similar to the integrated pattern of laser beam 126 described above with respect to print head 104 ( FIG. 3 ). Thus, print head 204 scans the integrated pattern of laser beam 226 over a portion of build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece.

[0047] 6 is a cross-sectional side view of yet another embodiment of a print head 304 in accordance with the present invention, where the print head 304 is self-contained and generally includes optical components configured to collimate and focus an emitted laser beam 306 onto the powder build plane 54. It should be understood that the print head 304 can be used in conjunction with the manufacturing apparatus 10 in a manner substantially similar to the print head 104 described above.

[0048] In particular, print head 304 includes one or more beam emitters 308 optically coupled to turning optics 314 optically coupled to beam homogenizer 312 optically coupled to projection element 316 (e.g., SLM), which is optically coupled to imaging optics 320 optically coupled to integrating optics 324.

[0049] In some embodiments, the beam emitter 308 generates a free-space laser beam 306 in which the transmission medium is air (“free space”) rather than glass (e.g., the glass in a fiber optic cable). In such embodiments, the beam emitter 308 is generally located outside of a housing 330. Additional components in the self-contained print head 304 include an energy recovery device 328 optically coupled to the projection element 316. Each of the beam homogenizer 312, turning optics 314, projection element 316, imaging optics 320, integrating optics 324, and energy recovery device 328 is at least partially mounted within the housing 330 using appropriate brackets and / or fasteners (not shown). The housing 330 has a front surface 332, a top surface 334, a back surface 336, and a bottom surface 338.

[0050] The beam emitter 308 is configured to generate a collimated laser beam 306 of sufficient energy to at least partially melt the powder at the build plane 54. The beam emitter 308 is generally disposed adjacent a front surface 332 of the housing 330. In some embodiments, the beam emitter 308 can include any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, a yttrium-based solid-state laser or a CO laser. Additionally, while the print head 304 is shown and described as including a single beam emitter 308, the print head 304 can include two or more beam emitters. For example, in one embodiment, the print head 304 can include a first beam emitter having a first power output or wavelength and a second beam emitter having a second power output or wavelength different from the first laser power output or wavelength, or at least two beam emitters having substantially the same power output and wavelength. In still other embodiments, print head 304 may include any combination of beam emitters that enable manufacturing apparatus 10 to function as described herein.

[0051] During operation of the print head 304, the beam emitter 308 transmits a free-space laser beam 306 that is collimated (e.g., a low-divergence, parallel beam) using a lens system (not shown). The free-space laser beam 306 has a round, Gaussian, or near-Gaussian energy distribution or profile and is provided to turning optics 314 located adjacent the back surface 336 of the housing 330 and below the beam emitter 308. In some embodiments, the turning optics 314 are dielectric mirrors or prisms. The turning optics 314 redirect the free-space laser beam 306, which has a round, Gaussian, or near-Gaussian energy distribution, to the beam homogenizer 312.

[0052] Beam homogenizer 312 is generally positioned above and away from turning optics 314 (e.g., toward the front side 332 of housing 330). Beam homogenizer 312 converts the round Gaussian or near-Gaussian profile of free-space laser beam 306 to have a uniform energy distribution that matches projection element 316. In other words, after homogenization by beam homogenizer 312, free-space laser beam 306 has a uniform energy distribution.

[0053] After homogenization by the beam homogenizer 312, the free-space laser beam 306 having a uniform energy distribution is directed toward the projection element 316. The projection element 316 is generally positioned adjacent to the top surface 334 of the housing 330 between its front surface 332 and back surface 334, and is positioned above the beam homogenizer 312. When the free-space laser beam 306 having a uniform energy distribution reaches the projection element 316, the projection element 316 projects multiple laser beams 318 having a pattern of laser light that forms an image or line. In some embodiments, the projection element 316 is an SLM. The projection element 316 is coupled to a cooling element 317 for cooling the projection element 316 from heat generated by the energy of the laser beam 306.

[0054] Furthermore, when the free-space laser beam 306 having a uniform energy distribution reaches the projection element 316, the projection element 316 directs a portion of the laser beam 306 to an energy recovery device 328. The energy recovery device 328 is generally disposed adjacent to the front surface 332 of the housing 330 and is located below the projection element 316. In some embodiments, the energy recovery device 328 is a heat sink or heat exchanger. The energy recovery device 328 is configured to recover any energy not used by the projection element 316. In some embodiments, the energy recovered by the energy recovery device 328 is used for preheating or post-heating the powder 48. In other embodiments, the energy recovery device 328 includes a photovoltaic cell (not shown) that generates power from the energy recovered by the energy recovery device 328 and can be reused within the manufacturing apparatus 10. In a further embodiment, the energy recovery device 328 is a beam dump that removes the energy recovered by the energy recovery device 328 from the manufacturing apparatus 10.

[0055] The multiple laser beams 318 generated by the projection element 316 are then directed to imaging optics 320 positioned below the projection element 316. The imaging optics 320 are comprised of transmissive or reflective elements that modify the magnification of the pattern formed by the multiple laser beams 318 into an expanded pattern of laser beam 322. For example, the expanded pattern of laser beam 322 may form an image similar to the expanded pattern of laser beam 122 described above with respect to printhead 104 (FIG. 3).

[0056] Imaging optics 320 deliver the magnified pattern of laser beam 322 to integrating optics 324. Integrating optics 324 are typically located below imaging optics 320 and adjacent bottom surface 338 of housing 330. In some embodiments, integrating optics 324 are cylindrical lenses or focusing diffractive optics. Integrating optics 324 are used to integrate the magnified pattern of laser beam 322 into an integrated pattern of laser beam 326 at build plane 54. For example, the integrated pattern of laser beam 326 may form an image similar to the integrated pattern of laser beam 126 described above with respect to print head 104 ( FIG. 3 ). Thus, print head 304 scans the integrated pattern of laser beam 326 over a portion of build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece.

[0057] 7 is a cross-sectional side view of another embodiment of a print head 404 in accordance with the present invention, where the print head 404 is self-contained and generally includes optical components configured to collimate and focus an emitted laser beam 406 onto the powder build plane 54. The print head 404 extends from the print head 104 described above and includes two or more projection elements 416a, 416b positioned next to each other to increase the total printed area at the build plane 54. It should be understood that the print head 404 can be used in conjunction with the manufacturing apparatus 10 in a substantially similar manner as the print head 104 described above.

[0058] In particular, the print head 404 includes one or more beam emitters 408 optically coupled to a collimator 410, which is optically coupled to a beam homogenizer 412 optically coupled to turning optics 414, which is optically coupled to a first projection element 416a (e.g., an SLM), which is optically coupled to a first imaging optic 420a, which is optically coupled to a first integrated optic 424a. The turning optics 414 is further optically coupled to a second projection element 416b, which is optically coupled to a second imaging optic 420b, which is optically coupled to a second integrated optic 424b. The first and second projection elements 416a, 416b are each configured to redirect a portion of the laser beam 406 to an energy recovery device 428.

[0059] Each of the beam emitter 408, collimator 410, beam homogenizer 412, turning optics 414, first and second projection elements 416a, 416b, first and second imaging optics 420a, 420b, first and second integrating optics 424a, 424b, and energy recovery device 428 is at least partially mounted within a housing 430 using appropriate brackets and / or fasteners (not shown). The housing 430 has a front surface 432, a top surface 434, a back surface 436, and a bottom surface 438.

[0060] The beam emitter 408 generally extends along the top surface 434 of the housing 430 and is configured to generate a laser beam 406 of sufficient energy to at least partially melt the powder at the build plane 54. In some embodiments, the beam emitter 408 can include any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, a yttrium-based solid-state laser or a CO laser. Additionally, although the print head 404 is shown and described as including a single beam emitter 408, the print head 404 can include two or more beam emitters. In one embodiment, for example, the print head 404 can include a first beam emitter having a first power output or wavelength and a second beam emitter having a second power output or wavelength that is different from the first laser power output or wavelength, or at least two beam emitters having substantially the same power output and wavelength. In still other embodiments, print head 404 may include any combination of beam emitters that enable manufacturing apparatus 10 to function as described herein.

[0061] During operation of the print head 404, the beam emitter 408, collimator 410, beam homogenizer 412, turning optics 414, and first projection element 416a are configured and operate substantially similarly to the corresponding components of the print head 104 described above. The operation of the turning optics 414 of the print head 404 differs from the operation of the turning optics 114 of the print head 104 in that the turning optics 414 also directs a portion of the laser beam 406 to the second projection element 416b. The second projection element 416b is then configured to direct a portion of the laser beam 406 to the energy recovery device 428. The energy recovery device 428 is then configured and operates substantially similarly to the energy recovery device 128 of the print head 104, except that the energy recovery device 428 is further configured to receive a portion of the laser beam 406 from the second projection element 416b.

[0062] The first and second projection elements 416 a, 416 b are generally disposed adjacent to the top surface 434 of the housing 430, with the first projection element 416 a positioned toward the back surface 436 of the housing 130 and the second projection element 416 b spaced apart from the first projection element 416 a (i.e., positioned toward the front surface 432 of the housing 130). Furthermore, the first and second projection elements 416 a, 416 b are positioned above the turning optics 414. In some embodiments, the first and second projection elements 416 a, 416 b are SLMs. The first and second projection elements 416 a, 416 b are also coupled to corresponding cooling elements 417 a, 417 b, respectively, for cooling the first and second projection elements 416 a, 416 b from heat generated by the energy of the laser beam 406.

[0063] When the laser beam 406 reaches the first and second projection elements 416a, 416b, each of the first and second projection elements 416a, 416b projects multiple laser beams 418a, 418b, respectively, having a pattern of laser light that forms an image or line. The multiple laser beams 418a, 418b generated by the first and second projection elements 416a, 416b are then directed toward imaging optics 420a, 420b positioned below the first and second projection elements 416a, 416b, respectively. The imaging optics 420a, 420b are configured and operate substantially similarly to the imaging optics 120 of the print head 104 described above. Thus, the imaging optics 420a, 420b generate magnified patterns of laser beams 422a, 422b, respectively. For example, the expansion pattern of each of laser beams 422a, 422b may form an image similar to the expansion pattern of laser beam 122 described above with respect to print head 104 (FIG. 3).

[0064] Imaging optics 420a, 420b then transmit the magnified patterns of laser beams 422a, 422b to corresponding integrating optics 424a, 424b. Integrating optics 424a, 424b are configured and operate in a manner substantially similar to integrating optics 124 of print head 104 described above. Accordingly, integrating optics 424a, 424b each generate a respective integrated pattern of laser beams 426a, 426b. For example, the integrated pattern of each of laser beams 426a, 426b may form an image similar to the integrated pattern of laser beam 126 described above with respect to print head 104 (FIG. 3). Thus, print head 404 scans the integrated pattern of laser beams 426a, 426b over a portion of build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece. In this regard, the expanded printhead 404 increases the total print area at the build plane 54 compared to the total print area of ​​the individual printheads 104 described above.

[0065] 8 is a cross-sectional side view of yet another embodiment of a print head 504 in accordance with the present invention, where the print head 504 is self-contained and generally includes optical components configured to collimate and focus the emitted beam onto the powder build plane 54. It should be understood that the print head 504 can be used in conjunction with the manufacturing apparatus 10 in a manner substantially similar to the print head 104 described above.

[0066] In particular, the print head 504 includes one or more beam emitters 508 that provide a laser beam via one or more control lines 506 (e.g., fibers). In some embodiments, the one or more beam emitters 508 can include any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, an yttrium-based solid-state laser or a CO laser. The one or more control lines 506 each direct a laser beam to a projection element 516 (e.g., a laser diode array). The projection element or laser diode array 516 is comprised of multiple print heads 518, each optically coupled to one of the one or more control lines 506 to receive a laser beam therefrom. In other embodiments, the one or more beam emitters 508 are power supplies that provide power via the one or more control lines 506. The one or more control lines 506 each direct power to the multiple print heads 518 of the laser diode array 516.

[0067] Additional components included within print head 504 include a heat exchanger or heat sink 517 mounted on top of laser diode array 516 and integrated optics 524 positioned below laser diode array 516. Each of one or more beam emitters 508, one or more control lines 506, laser diode array 516, heat sink 517, and integrated optics 524 is at least partially mounted within housing 530. Housing 530 has a front surface 532, a top surface 534, a back surface 536, and a bottom surface 538.

[0068] In the laser diode array 516 shown in FIG. 8 , only three printheads 518 are visible. However, it should be noted that the laser diode array 516 includes three additional printheads 518 that are not visible from the visual field. In this regard, the following description describes the configuration and operation of the laser diode array with respect to the three visible printheads 518. However, it should be understood that the three printheads 518 that are not visible from the visual field operate in a substantially similar manner. The laser diode array 516 is generally disposed between the front and back sides 536 of the housing 530 and adjacent the bottom side 538 of the housing 530.

[0069] The beam emitter 508 is generally disposed adjacent the front surface 532 of the housing 530 and is configured to generate laser beam(s) (not shown) of sufficient energy to at least partially melt the powder at the build plane 54. Although the print head 504 is shown and described as including a single beam emitter 508, the print head 504 may include two or more beam emitters. In one embodiment, for example, the print head 504 may include a first beam emitter having a first power output or wavelength and a second beam emitter having a second power output or wavelength that is different from the first laser power output or wavelength, or at least two beam emitters having substantially the same power output and wavelength. In still other embodiments, the print head 504 may include any combination of beam emitters that enables the manufacturing apparatus 10 to function as described herein.

[0070] During operation of the print head 504, the beam emitter 508 first sends a laser beam to the laser diode array 516 through each of the one or more control lines 506, such that each print head 518 is optically coupled to one of the one or more control lines 506. In another embodiment, the beam emitter 508 first sends power to the laser diode array 516 through each of the one or more control lines 506, such that each print head 518 is electrically powered. When the one or more control lines 506 send a laser beam (or power) to each print head 518 of the laser diode array 516, each print head 518 projects multiple laser beams (not shown) having a pattern of laser light that forms an image or line. Additionally, the laser diode array 516 directs a portion of the laser beam to a heat sink 517. The heat sink 517 is configured to recover any energy not used by the laser diode array 516. Additionally, the heat sink 517 acts as a cooling element to cool the laser diode array 516 from the heat generated by the energy of the laser beam (or power) transmitted through one or more control lines 506 .

[0071] Each print head 518 then delivers multiple laser beams (not shown) having a pattern of laser light that forms an image or line to integrating optics 524. The integrating optics 524 are positioned below the laser diode array 516 and adjacent the bottom surface 538 of the housing 530. In some embodiments, the integrating optics 524 are cylindrical lenses or focusing diffractive optics. The integrating optics 524 are used to integrate the multiple laser beams (not shown) produced by each of the print heads 518 and having a pattern of laser light that forms an image or line in the integrated pattern of the laser beams 526 at the build plane 54. For example, the integrated pattern of each of the laser beams 526 can form an image similar to the integrated pattern of the laser beam 126 described above with respect to the print head 104 (FIG. 3). Thus, the print head 504 scans the integrated pattern of the laser beams 526 over a portion of the build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece.

[0072] 9 is a cross-sectional side view of yet another embodiment of a print head 604 in accordance with the present invention, which is self-contained and generally includes optical components configured to collimate and focus an emitted beam (not shown) onto the powder build plane 54. The print head 604 extends from the print head 504 described above to include a larger projection element or laser diode array 516 to increase the total print area at the build plane 54. It should be understood that the print head 604 can be used in conjunction with the manufacturing apparatus 10 in a manner substantially similar to the print head 104 described above.

[0073] In particular, the print head 604 includes one or more beam emitters 608 that provide a laser beam via one or more control lines 606 (e.g., fibers). In some embodiments, the one or more beam emitters 608 can include any suitable type of laser that enables the manufacturing apparatus 10 to function as described herein, such as a fiber laser or fiber-delivered laser, a direct diode or fiber-delivered direct diode, a Raman fiber laser, and in some embodiments, an yttrium-based solid-state laser or a CO laser. The one or more control lines 606 each direct a laser beam to a projection element 616 (e.g., a laser diode array). The projection element or laser diode array 616 is comprised of multiple print heads 618, each optically coupled to one of the one or more control lines 606 to receive a laser beam therefrom. In other embodiments, the one or more beam emitters 608 are power supplies that provide power via the one or more control lines 606. The one or more control lines 606 each direct power to the multiple print heads 618 of the laser diode array 616.

[0074] Additional components included within print head 604 include a heat exchanger or heat sink 617 mounted on top of laser diode array 616 and integrated optics 624 positioned below laser diode array 616. Each of one or more beam emitters 608, one or more control lines 606, laser diode array 616, heat sink 617, and integrated optics 624 is at least partially mounted within housing 630. Housing 630 has a front surface 632, a top surface 634, a back surface 636, and a bottom surface 638.

[0075] In the laser diode array 616 shown in FIG. 9 , only six printheads of the plurality of printheads 618 are visible. However, it should be noted that the laser diode array 616 comprises the plurality of printheads 618 and includes an additional six printheads not visible from view. In this regard, the following description describes the configuration and operation of the laser diode array with respect to the six visible printheads of the plurality of printheads 618. However, it should be understood that the six printheads not visible from view of the plurality of printheads 618 operate in a substantially similar manner. The laser diode array 616 is generally disposed between a front side and a back side 636 of the housing 630 and adjacent a bottom side 638 of the housing 630.

[0076] The beam emitter 608 is generally disposed adjacent the front surface 632 of the housing 630 and is configured to generate laser beam(s) (not shown) of sufficient energy to at least partially melt the powder at the build plane 54. Although the print head 604 is shown and described as including a single beam emitter 608, the print head 604 may include two or more beam emitters. In one embodiment, for example, the print head 604 may include a first beam emitter having a first power output or wavelength and a second beam emitter having a second power output or wavelength that is different from the first laser power output or wavelength, or at least two beam emitters having substantially the same power output and wavelength. In still other embodiments, the print head 604 may include any combination of beam emitters that enables the manufacturing apparatus 10 to function as described herein.

[0077] During operation of the print head 604, the beam emitter 608 first sends a laser beam to the laser diode array 616 through each of the one or more control lines 606, such that each print head 618 is optically coupled to one of the one or more control lines 606. In other embodiments, the beam emitter 608 first sends power to the laser diode array 616 through each of the one or more control lines 606, such that each print head 618 is electrically powered. When the one or more control lines 606 send a laser beam (or power) to each print head 618 of the laser diode array 616, each print head 618 projects multiple laser beams (not shown) having a pattern of laser light that forms an image or line. Additionally, the laser diode array 616 directs a portion of the laser beam to a heat sink 617. The heat sink 617 is configured to recover any energy not used by the laser diode array 616. Additionally, the heat sink 617 acts as a cooling element to cool the laser diode array 616 from the heat generated by the energy of the laser beam (or power) transmitted through one or more control lines 606 .

[0078] Each print head 618 then delivers multiple laser beams (not shown) having a pattern of laser light that forms an image or line to integrating optics 624. The integrating optics 624 are positioned below the laser diode array 616 and adjacent the bottom surface 638 of the housing 630. In some embodiments, the integrating optics 624 are cylindrical lenses or focusing diffractive optics. The integrating optics 624 are used to integrate the multiple laser beams (not shown) produced by each of the print heads 618 and having a pattern of laser light that forms an image or line in the integrated pattern of the laser beams 626 at the build plane 54. For example, the integrated pattern of each of the laser beams 626 may form an image similar to the integrated pattern of the laser beam 126 described above with respect to the print head 104 ( FIG. 3 ). Thus, the print head 604 scans the integrated pattern of the laser beams 626 over a portion of the build plane 54 where it is desired to melt or fuse powder to form a layer of the workpiece. In this regard, the expanded printhead 604 increases the total print area at the build plane 54 compared to the total print area of ​​the individual printheads 504 described above.

[0079] 10 is a cross-sectional side view of another embodiment of a printhead 714 in accordance with the present invention. The printhead 714 is similar to the printhead 104 shown in FIG. 3. Accordingly, like numerals are used to refer to like figures. It should be understood that the printhead 714 can be used in conjunction with the manufacturing apparatus 10 in a substantially similar manner as the printhead 104 described above.

[0080] The print head 714 is self-contained and generally includes optical components configured to collimate and focus the emitted beam 106 onto the build plane 54. In particular, the print head 714 includes one or more beam emitters 108 optically coupled to a collimator 110, which is optically coupled to a beam homogenizer 712. The beam homogenizer 712 may include delivery optics. The beam homogenizer 712 is optically coupled to turning optics 114, which are optically coupled to a projection element 716 (e.g., an SLM), which is optically coupled to imaging optics 720. The print head 714 may not include separate integrated optics 124, as shown in FIG. 3, for example. Instead, the integrated element may be integrated into the projection element 716. In some embodiments, the projection element 716 may be an LCOS device.

[0081] FIG. 11 is a flow diagram of a method 700 for transmitting multiple laser beams to a build plane 54 of a manufacturing tool 10, as shown in FIGS. 1-3. The method 700 includes, at step 702, generating one or more laser beams 106 using one or more beam emitters 108. The method 700 further includes, at step 704, receiving the laser beams 106 at projection elements 116 in a housing 130 of the print head 104 and projecting multiple laser beams 118 using the projection elements 116. The method 700 also includes, at step 706, integrating the multiple laser beams 118 into an integrated pattern of laser beams 126 using integrating optics 124 in the housing 130 of the print head 104. The method 400 further includes, at step 708, directing the integrated pattern of laser beams 126 toward the build plane 54 of the manufacturing tool 10 using the integrating optics 124.

[0082] From the above, it should be understood that what is defined herein is a self-contained print head containing one or more light sources of varying power and wavelength. The print head utilizes multiple laser beams to fuse the powdered build material instead of the traditional single-beam-per-scanner approach. This method produces less soot and greater energy efficiency in the additive manufacturing device. Furthermore, compared to traditional scanners, this process is cheaper, more robust, and can be calibrated before installation. In addition, the print head is modular, so the build area of ​​the additive manufacturing device can be increased by adding additional modules without soot and heat dissipation issues. In this way, the print head is scalable to increase the consolidation rate of the powdered build material and the size of the parts that can be produced by the additive manufacturing device. Beam shaping, coupling, steering, and delivery optics for powder processing and pre- and post-heating of the welding area are contained within the print head.

[0083] Further aspects of the embodiments described herein are provided by the following subject matter.

[0084] a print head of an additive manufacturing apparatus comprising: a housing; a projection element disposed in the housing, the projection element configured to receive one or more laser beams generated by a beam emitter and project a plurality of projected laser beams in a pattern; and an integrating optics disposed in the housing and positioned below the projection element, the integrating optics configured to integrate the pattern of the plurality of projected laser beams into an integrated pattern of projected laser beams;

[0085] Any preceding printhead, further including a collimator at a distal end of the beam emitter and disposed in the housing; a beam homogenizer below the collimator and disposed in the housing; and turning optics below the beam homogenizer and disposed in the housing.

[0086] Any of the preceding printheads, further comprising one or more imaging optics disposed below said projection element.

[0087] Any of the preceding printheads, further including a heat sink disposed on the housing of the printhead, wherein the projection element is further configured to direct a portion of one or more of the laser beams toward the heat sink disposed on the housing of the printhead.

[0088] Any of the preceding printheads, further comprising a plurality of beam emitters configured to generate one or more of said laser beams.

[0089] Any of the preceding printheads, wherein the one or more laser beams generated by the beam emitters are free-space laser beams.

[0090] Any of the preceding printheads further including two or more projection elements disposed in said housing.

[0091] Any preceding printhead wherein the integrated optics are integral with the projection element.

[0092] 1. An additive manufacturing device comprising: a build platform supporting a powdered build material, the powdered build material defining a build plane of the build platform; and a print head, the print head comprising: a housing; a beam emitter configured to generate one or more laser beams; a projection element disposed in the housing, the projection element configured to receive the one or more laser beams and project a plurality of projected laser beams in a pattern; and integrating optics disposed in the housing and below the projection element, the integrating optics configured to integrate the pattern of the plurality of projected laser beams into an integrated pattern of projected laser beams; the print head configured to direct the integrated pattern of projected laser beams onto the build plane and melt a portion of the powdered build material at the build plane with the integrated pattern of projected laser beams.

[0093] 10. Any preceding additive manufacturing apparatus, wherein the print head further includes a collimator disposed in the housing, the collimator optically coupled to the beam emitter.

[0094] 10. Any preceding additive manufacturing apparatus, wherein the print head further includes a beam homogenizer disposed in the housing, the beam homogenizer optically coupled to the collimator.

[0095] Any preceding additive manufacturing apparatus, wherein the print head further includes turning optics disposed in the housing, the turning optics optically coupled to the beam homogenizer and configured to direct the one or more laser beams towards the projection element.

[0096] Any preceding additive manufacturing apparatus, wherein the print head further comprises one or more imaging optics disposed in the housing, the one or more imaging optics optically coupled to the projection element.

[0097] 10. Any of the preceding additive manufacturing apparatus, wherein the projection element is a digital micromirror device.

[0098] 10. Any of the preceding additive manufacturing apparatus, further comprising a computing device that controls the pattern of the plurality of projected laser beams projected by the projection element.

[0099] Any of the preceding additive manufacturing apparatus, further comprising a soot collection system mounted on the exterior of the housing of the print head.

[0100] 1. A laser beam delivery method for delivering multiple laser beams onto a build plane of an additive manufacturing device, comprising: generating one or more laser beams with a beam emitter; receiving the one or more laser beams with a projection element disposed in a print head housing; projecting the multiple projected laser beams in a pattern with the projection element; integrating the pattern of the multiple projected laser beams into an integrated pattern of projected laser beams with integrating optics disposed in the housing; and directing the integrated pattern of projected laser beams toward the build plane.

[0101] 10. Any of the preceding laser beam delivery methods, further comprising: collimating one or more of the laser beams to have a round Gaussian energy distribution; homogenizing one or more of the laser beams to have a uniform energy distribution; and redirecting one or more of the laser beams with the uniform energy distribution towards the projection element.

[0102] 10. Any of the preceding laser beam delivery methods, further comprising: magnifying the pattern of the plurality of projected laser beams projected by the projection element; and directing the magnified pattern towards the integrating optics.

[0103] 10. Any preceding method of laser beam delivery, further comprising directing, with the projection element, a portion of one or more of the laser beams toward a heat sink, the heat sink being disposed in the housing of the printhead.

[0104] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the scope of the claimed subject matter. Thus, it is intended that the present specification cover modifications and variations of the various embodiments described herein, provided that such modifications and variations come within the scope of the appended claims and their equivalents.

[0105] (CROSS-REFERENCE TO RELATED APPLICATIONS)

[0106] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 465,388, filed May 10, 2023, entitled "Print Module for Additive Manufacturing Apparatus," the entire contents of which are incorporated herein by reference.

Claims

1. Housing and a projection element disposed in the housing, the projection element being a digital micromirror device configured to receive one or more laser beams from a beam emitter and to project a plurality of projected laser beams in a pattern; an integrating optic disposed on the housing and positioned below the projection element, the integrating optic configured to integrate the patterns of the plurality of projected laser beams into an integrated pattern of projected laser beams; one or more imaging optics disposed within the housing; Including, the one or more imaging optics are optically coupled to the projection element; the one or more imaging optics may be transmissive or reflective elements; and changing the magnification of the pattern formed by the plurality of projected laser beams to form an enlarged pattern. Additive manufacturing equipment print head.

2. a collimator disposed at the distal end of the beam emitter in the housing; a beam homogenizer disposed in the housing below the collimator; turning optics disposed in the housing below the beam homogenizer; The printhead of claim 1 further comprising:

3. The one or more imaging optics are disposed below the projection element. The printhead described.

4. further comprising a heat sink disposed on the housing of the printhead; the projection element is further configured to direct a portion of one or more of the laser beams toward the heat sink disposed in the housing of the print head. The printhead of claim 1 .

5. The printhead of claim 1 , further comprising a plurality of beam emitters configured to generate one or more of the laser beams.

6. one or more of the laser beams generated by the beam emitter are free-space laser beams; The printhead of claim 1 .

7. The printhead of claim 1 further comprising two or more projection elements disposed in the housing.

8. The printhead of claim 1 , wherein the integrated optics are integrated into the projection element.

9. a build platform supporting a powdered build material, the powdered build material defining a build plane of the build platform; The print head and Including, The print head includes: Housing and a beam emitter configured to generate one or more laser beams; a projection element disposed in the housing, the projection element being a digital micromirror device configured to receive one or more of the laser beams and project a plurality of projected laser beams in a pattern; an integrating optic disposed on the housing and positioned below the projection element, the integrating optic configured to integrate the patterns of the plurality of projected laser beams into an integrated pattern of projected laser beams; Including, the print head is configured to direct the integrated pattern of projected laser beams onto the build plane such that the integrated pattern of projected laser beams melts a portion of the powdered build material at the build plane; the printhead further includes one or more imaging optics disposed within the housing; the one or more imaging optics are optically coupled to the projection element; the one or more imaging optics may be transmissive or reflective elements; and changing the magnification of the pattern formed by the plurality of projected laser beams to form an enlarged pattern. Additive manufacturing equipment.

10. the printhead further includes a collimator disposed in the housing; the collimator is optically coupled to the beam emitter; 10. The additive manufacturing device of claim 9.

11. the printhead further includes a beam homogenizer disposed in the housing; the beam homogenizer is optically coupled to the collimator. The additive manufacturing device of claim 10.

12. the printhead further includes turning optics disposed in the housing; the turning optics are optically coupled to the beam homogenizer and configured to direct one or more of the laser beams toward the projection element.

12. The additive manufacturing device of claim 11.

13. further comprising a computing device that controls the pattern of the plurality of projected laser beams projected by the projection element.

10. The additive manufacturing device of claim 9.

Images