Additive Manufacturing Head Positioning for Variable Laser Spot Size
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in controlling the size of the laser beam irradiation region on a workpiece surface due to the delicacy of optical components, requiring precise and minimal movement to maintain accuracy.
Innovation Solution
A workpiece processing method that involves controlling the distance between the workpiece and the laser beam emitter to adjust the size of the irradiation region, combined with swiveling the additive-manufacturing head to align the laser beam with different workpiece regions, allowing precise and efficient additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the convex lens is moved in the optical axis direction to control the size of the irradiation region, then the manufacturing precision is improved, but the device complexity increases and the reliability decreases due to the delicate optical components
Solution Approach 1:
Instead of moving the convex lens to control irradiation region size, the patent inverts the approach by moving the workpiece relative to the fixed optical components. The workpiece is positioned at different distances from the laser beam emitter along the optical axis, achieving variable irradiation region sizes without moving any optical components. This resolves the contradiction by eliminating the complex lens movement mechanism while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the mechanical lens movement system with a workpiece positioning system. Rather than mechanically moving delicate optical components to change focal spot size, the system uses workpiece translation along the optical axis to achieve the same effect. This substitution eliminates the need for precision lens positioning mechanisms and reduces device complexity while maintaining the ability to control irradiation region size.
2Adaptability or versatility
If the convex lens is moved to adjust the irradiation region size for different workpiece regions, then the adaptability is improved, but the reliability decreases due to repeated movement of delicate optical components
Solution Approach 1:
The patent inverts the control approach by keeping optical components fixed and moving the workpiece instead. The workpiece is positioned at different distances from the laser beam emitter to achieve different irradiation region sizes, providing adaptability for different workpiece regions without requiring repeated movement of delicate optical components. This maintains system reliability while preserving adaptability.
Solution Approach 2:
The patent segments the processing approach into multiple workpiece positioning states rather than moving optical components. Each workpiece position corresponds to a specific irradiation region size suitable for different processing scenarios. This segmentation allows the system to adapt to different workpiece regions by simply changing workpiece position, eliminating repeated optical component movement and associated reliability issues.
3Manufacturing precision
If the optical components are driven frequently to control laser beam irradiation size, then the manufacturing precision is improved, but the ease of operation worsens due to the delicacy of optical components
Solution Approach 1:
The patent inverts the operational approach by making the workpiece movable rather than the optical components. Operators control irradiation region size by positioning the workpiece at different distances from the fixed laser beam emitter, eliminating the need to handle and move delicate optical components. This improves ease of operation while maintaining manufacturing precision through simple workpiece positioning.
Solution Approach 2:
The patent replaces the optical component movement mechanism with a workpiece positioning system. Instead of requiring operators to move delicate lenses and mirrors to change irradiation size, the system uses workpiece translation along the optical axis. This substitution significantly improves ease of operation by eliminating sensitive optical handling while preserving precise irradiation region control.
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
This method enables precise additive manufacturing for smaller regions and efficient manufacturing for larger regions by adjusting the irradiation size of the laser beam, maintaining optical system reliability and simplifying the additive-manufacturing head structure.
Implementation Method 1
a laser beam emitter that emits the ring-shaped laser beam toward the workpiece
Implementation Method 2
performing additive manufacturing for a workpiece by emitting a ring-shaped laser beam from an additive-manufacturing head toward the workpiece
Implementation Method 3
a first axicon lens and a second axicon lens arranged to face each other, and a convex lens disposed between the first axicon lens and the second axicon lens, and causes laser beam incident on the first axicon lens to exit from the second axicon lens as ring-shaped laser
Data Source
AI summary
A workpiece processing method includes performing additive manufacturing for a first region of a workpiece; and performing additive manufacturing for a second region of the workpiece, the second region being smaller in width than the first region. The performing additive manufacturing for the first region includes positioning an additive-manufacturing head and the workpiece relative to each other so as to make a distance between the workpiece and a laser beam emitter in the additive-manufacturing head equal to a first distance. The performing additive manufacturing for the second region includes positioning the additive-manufacturing head and the workpiece relative to each other so as to make the distance between the workpiece and the laser beam emitter in the additive-manufacturing head equal to a second distance that is smaller than the first distance.