Addressable Laser Array for Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current laser systems, particularly infrared-based additive manufacturing systems, face limitations in build volume, build speed, and quality due to challenges in beam alignment, power management, and absorption issues, leading to defects like spatter and porosity in the final parts.
Innovation Solution
The development of a 1-D or 2-D array of laser beams with a precision gantry system for parallel fusion of powder, real-time temperature monitoring, and a sealed enclosure to minimize porosity and residual stress, along with a micro-processing system for optimal build strategy, enables high-throughput additive manufacturing without keyhole welding mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If infrared laser beam is used in additive manufacturing system, then laser power can be increased, but build volume is limited by finite size of scanning system and spot size
Solution Approach 1:
The patent divides the single laser beam into multiple parallel laser beams arranged in an array configuration. This segmentation allows simultaneous processing of multiple locations on the powder bed, effectively increasing the build volume without requiring a larger scanning system footprint. The array of laser beams can be independently controlled to address different regions of the build chamber.
Solution Approach 2:
The patent transitions from a single-point laser processing approach to a multi-point parallel processing approach by arranging laser beams in a two-dimensional array. This dimensional expansion from 1D scanning to 2D parallel processing increases the effective build volume and addressable footprint on the powder bed.
2Power
If infrared laser beam is used in additive manufacturing system, then laser power can be increased, but build speed is limited by absorption of laser beam by powder material
Solution Approach 1:
The patent segments the laser energy delivery into multiple parallel beams that can simultaneously process different regions of the powder bed. This parallel processing approach overcomes the absorption limitations of infrared light by distributing the total laser power across multiple beam paths, allowing faster overall processing speed while maintaining adequate energy delivery to each processed region.
Solution Approach 2:
The patent applies partial action by using multiple laser beams at optimized power levels rather than a single excessive-power beam. This allows better control of energy absorption and reduces problems like spatter and porosity while achieving faster build speeds through parallel processing of multiple powder bed regions.
3Device complexity
If single laser beam is used for melting and fusing powder, then process is simple, but keyhole welding mode causes spatter and porosity defects
Solution Approach 1:
The patent uses multiple lower-power laser beams in parallel to melt and fuse the powder instead of a single high-power beam. This segmentation of the melting process prevents the formation of keyhole welding mode, thereby eliminating spatter and porosity defects while maintaining process control. Each beam operates in a controlled conduction mode rather than keyhole mode.
Solution Approach 2:
The patent changes the laser processing parameters by using multiple beams at optimized power levels that prevent keyhole formation. This parameter optimization allows the system to operate in a stable conduction welding mode that produces high-quality parts without the defects associated with keyhole welding, while still achieving efficient powder melting and fusion.
4Productivity
If array of laser beams is used for parallel fusion, then build speed is enhanced, but beam alignment and power management become difficult
Solution Approach 1:
The patent employs a unified control system that manages all laser beams in the array through a single interface and control architecture. This universal control approach handles beam alignment, power management, and coordination across all beams simultaneously, making the complex multi-beam system as easy to operate as a single-beam system while achieving enhanced build speeds through parallel processing.
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 approach enhances build speed and quality by maintaining beam brightness and power while reducing defects, achieving stable and uniform welds with improved surface roughness and part density.
Implementation Method 1
directly fusing the powder in a parallel fashion
Implementation Method 2
melting and fusing the powder to the lower layer or substrate
Implementation Method 3
real time temperature monitoring camera such as a thermal imaging camera
Data Source
AI summary
There is provided assemblies for combining a group of laser sources into a combined laser beam. There is further provided a blue diode laser array that combines the laser beams from an assembly of blue laser diodes. There are provided laser processing operations and applications using the combined blue laser beams from the laser diode arrays and modules.