3D Beam Splitting Optics for Accurate Multi-Spot Shaping
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Solution Overview
Problem
Conventional 3D shaping apparatuses using linear light irradiation face challenges in maintaining shape accuracy due to temperature variations in the shaping material, leading to inconsistent melting and expansion, resulting in deviations from the intended shape.
Innovation Solution
A 3D shaping apparatus employing a beam irradiation unit, spatial light modulator, splitting optical system with lens arrays, and a controller to adjust the light beam's intensity and scanning path, forming multiple spots on the shaping material to control temperature distribution and reduce expansion, thereby enhancing shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If linear light irradiates the shaping material to increase shaping speed, then productivity is improved, but temperature varies in the irradiated region causing shape accuracy to deteriorate
Solution Approach 1:
The patent divides a single linear light beam into multiple parallel light beams using a lens array. Each light beam independently irradiates a specific region of the shaping material, creating multiple discrete heating zones instead of one continuous linear irradiation. This segmentation prevents temperature variation across a single linear region while maintaining high-speed shaping capability.
2Device complexity
If a single light beam is used to irradiate the shaping material, then device complexity is reduced, but shape accuracy deteriorates due to temperature distribution variations
Solution Approach 1:
The patent employs a lens array that divides one light beam into multiple parallel beams, creating multiple irradiation spots on the shaping material. This approach maintains relatively simple device architecture while achieving uniform temperature distribution through multiple discrete heating zones, thereby improving shape accuracy.
3Productivity
If linear light scanning is performed to melt shaping material, then productivity increases, but melted material flows according to temperature distribution causing surface expansion and shape accuracy to decrease
Solution Approach 1:
By dividing the linear light beam into multiple parallel beams that create separate irradiation spots, the patent prevents continuous melted material flow along a linear path. Each spot creates localized melting with controlled material flow, preventing the surface expansion and shape deviations that occur with single linear scanning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves high shape accuracy by narrowing the flowable range of melted material, reducing peripheral expansion, and optimizing the intensity distribution of spots to prevent spatter and fume, while allowing for adjustable beam count and scanning speed to accommodate various melting points and improve throughput.
Implementation Method 1
irradiates a shaping material such as a metal material (powder) with light from a laser light source and scans the shaping material with the light to melt or sinter the shaping material
Implementation Method 2
a splitting optical system including at least one lens array having a plurality of lenses arranged along the first axis and configured to split the light beam modulated by the spatial light modulator into a plurality of light beams
Implementation Method 3
When the temperature varies, the melted shaping material flows according to its temperature distribution and surface tension
Data Source
AI summary
A 3-dimensional shaping apparatus manufactures a 3-dimensional shaped object. The 3-dimensional shaping apparatus includes a beam irradiation unit, a spatial light modulator, a splitting optical system, and a scanning unit. The beam irradiation unit emits a light beam. The spatial light modulator spatially modulates the light beam emitted by the beam irradiation unit at least on the first axis. The splitting optical system includes at least one lens array having a plurality of lenses arranged along the first axis and splits the light beam modulated by the spatial light modulator into a plurality of light beams by the lens array. The scanning unit scans the shaping material with the plurality of light beams from the splitting optical system.