3D Laser Module Layout for Homogeneous Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laser printing systems for 3D additive manufacturing face challenges in reliability and efficiency due to reliance on single high-power lasers or arrays, which can result in malfunctions and increased service costs, and struggle to provide homogeneous illumination across large areas.
Innovation Solution
A laser printing system utilizing multiple semiconductor laser arrays, where each pixel is illuminated by a diffuse image of multiple lasers, reducing the reliance on individual laser performance and enhancing reliability, with optical elements like lenses or micro-lens arrays to achieve more even energy distribution and continuous illumination across the work plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single high-power laser is used, then the illumination intensity is sufficient for processing, but the reliability decreases due to higher risk of malfunction and increased service costs
Solution Approach 1:
The patent divides a single high-power laser source into multiple lower-power semiconductor laser arrays. Each array contributes a portion of the total required illumination intensity, thereby distributing the functional load. This segmentation reduces the stress on individual laser components and provides redundancy, so if one array fails, others can maintain operation, thus improving reliability while achieving sufficient total power through cumulative output.
Solution Approach 2:
The patent changes the operational parameters by using multiple semiconductor laser arrays operating at lower individual power levels compared to a single high-power laser. By adjusting the number of active arrays and their individual output parameters, the system achieves the required total illumination intensity while operating in a more reliable regime where individual components are less prone to failure.
2Reliability
If multiple semiconductor laser arrays are used to improve reliability, then the illumination becomes more homogeneous, but the device complexity increases
Solution Approach 1:
The patent combines multiple semiconductor laser arrays into a unified laser module architecture where the arrays are integrated with common control and optical elements. This merging approach allows the system to achieve the reliability benefits of multiple lasers while managing complexity through unified design and control mechanisms, rather than treating each laser as a separate complex subsystem.
Solution Approach 2:
The laser module design incorporates multiple semiconductor laser arrays that can operate in different configurations and modes. The system provides multi-functionality by allowing selective activation of arrays based on processing requirements, enabling the same hardware infrastructure to serve multiple operational scenarios, thereby justifying the complexity through enhanced versatility and reliability.
3Manufacturing precision
If laser arrays are imaged to pixels with sharp focus, then the manufacturing precision is high, but the illumination homogeneity decreases
Solution Approach 1:
The patent applies different optical quality requirements to different aspects of the imaging. Each laser array is imaged with sufficient precision to define pixel boundaries accurately (local precision), while the overall illumination pattern across the working plane is optimized for homogeneity (local uniformity). This is achieved by controlling the imaging parameters and optical element positioning to balance these competing local requirements.
Solution Approach 2:
The patent prioritizes homogeneous illumination across the working plane by configuring the imaging of multiple laser arrays such that their combined light distribution is uniform. The optical elements and array positioning are designed to ensure that the superposition of multiple laser beams creates an even illumination pattern, accepting some trade-off in peak pixel definition precision to achieve overall uniformity.
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 system achieves improved reliability and efficiency by distributing energy more homogeneously across the work plane, allowing for higher throughput and reduced risk of malfunctions, as the failure of one laser does not significantly impact the overall performance, and enables more precise control over energy input for 3D printing.
Implementation Method 1
The optical element is adapted to image laser light emitted by the laser arrays, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in a working plane of the laser printing system.
Implementation Method 2
The laser module comprises at least two laser arrays of semiconductor lasers
Implementation Method 3
laser light emitted by the laser arrays
Data Source
AI summary
The invention describes a laser printing system (100) for illuminating an object moving relative to a laser module of the laser printing system (100) in a working plane (180), the laser module comprising at least two laser arrays of semiconductor lasers and at least one optical element, wherein the optical element is adapted to image laser light emitted by the laser arrays, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in the working plane of the laser printing system, and wherein the laser printing system is a 3D printing system for additive manufacturing and wherein two, three, four or a multitude of laser modules (201, 202) are provided, which are arranged in columns (c1, c2) perpendicular to a direction of movement (250) of the object in the working plane (180), and wherein the columns are staggered with respect to each other such that a first laser module (201) of a first column of laser modules (c1) is adapted to illuminate a first area (y1) of the object and a second laser module (202) of a second column (c2) of laser modules is adapted to illuminate a second area (y2) of the object, wherein the first area (y1) is adjacent to the second area (y2) such that continuous illumination of the object is enabled.